KR20200036842A - Optionally visible metal trim and method of manufacturing the same - Google Patents

Abstract

The object trim, which appears to be a metal, is a transparent or translucent substrate defining an upper surface and a lower surface, an opaque layer applied to one of the upper and lower surfaces of the substrate, the opaque layer defining one or more openings through which light can pass; And one or more translucent metal effect layers applied to the top surface of the opaque layer when the opaque layer is applied to the top surface of the substrate or to the top surface of the substrate when the opaque layer is applied to the bottom surface of the substrate. . The one or more metal effect layers include one or more layers of digitally printed metal material or one or more metal effect paints. A light source is arranged below the lower surface of the substrate and produces light passing through the substrate, one or more openings, and one or more metal effect layers.

Description

Optionally visible metal trim and method of manufacturing the same

Cross reference to related applications

This application is a PCT international application claiming the benefit of Spanish application P201730785 filed June 9, 2017 and Spanish application P201830556 filed June 7, 2018. The disclosure content of the above application is incorporated herein by reference in its entirety.

Technology field

This application relates generally to decorative trim, and more particularly to an optional metallic looking trim and methods of manufacturing the same.

Decorative trim is applied to emphasize or enhance the visual appearance of the object. For example, vehicle interior and exterior components often have decorative trim. To further enhance the visual appearance, a light source can be incorporated into the decorative trim to create a lighting effect. Chrome plating is an example of a decorative trim, which is often used due to its high gloss appearance. However, chromium plating can have a negative impact on the environment, for example due to the use of a hexavalent chromium bath. Chromium plating is also formed of one or more opaque metal layers that do not allow light to pass through, and therefore cannot be used in connection with the backlight illumination effect. Thus, while such a decorative trim works well for its intended purpose, there remains a need for improvement in the related art.

According to one aspect of the invention, a trim for an object is provided. In one exemplary embodiment, the trim is a transparent or translucent substrate defining an upper surface, an opaque layer applied to the upper surface of the substrate, the opaque layer defining one or more openings through which light can pass, and And one or more translucent metal effect layers applied to the top surface of the opaque layer.

In some embodiments, the one or more metal effect layers include one or more metal effect paint layers. In other embodiments, the one or more metal effect layers include one or more layers of digitally printed metal effect materials.

In some embodiments, the one or more metal effect layers include only one or more base coating layers of metal effect paint. In another embodiment, one or more metal effect layers are applied to (i) a translucent primer layer applied to a portion of the substrate corresponding to the top surface and one or more openings of the opaque layer and (ii) a metal effect applied to the top surface of the primer layer. And one or more translucent base coating paint layers of paint. In some embodiments, the one or more metal effect layers further include a transparent or translucent top coating layer applied to the top surface of the one or more base coating paint layers, the top coating layer protecting and enhancing the metal effect of the one or more metal effect layers Order.

In some embodiments, at least one of the primer layer and the top coating layer comprises metal particles to further enhance the metal effect of the one or more metal effect layers. In some embodiments, the top coating layer is at least one of tinted and tinted to further enhance the metallic effect of the one or more metal effect layers.

In some embodiments, the trim is an selectively illuminable trim further comprising a light source arranged below the lower surface of the substrate, the light source through the substrate, one or more openings defined by the opaque layer, and one or more metal effect layers It is configured to output light. In some embodiments, the trim further includes a light guide disposed between the light source and the lower surface of the substrate, the light guide being configured to distribute light output from the light source.

According to another aspect of the invention, a trim for an object is provided. In one exemplary embodiment, the trim comprises a transparent or translucent substrate defining an upper surface and a lower surface, an opaque layer applied to the lower surface of the substrate, the opaque layer defining one or more openings through which light can pass, and And one or more translucent metal effect layers applied to the top surface of the substrate.

In some embodiments, the one or more metal effect layers include one or more metal effect paint layers. In other embodiments, the one or more metal effect layers include one or more layers of digitally printed metal effect materials.

In some embodiments, the one or more metal effect layers include only one or more base coating layers of metal effect paint. In other embodiments, the one or more metal effect layers include (i) a translucent primer layer applied to the top surface of the substrate and (ii) one or more translucent base coating paint layers of metal effect paint applied to the top surface of the primer layer. In some embodiments, the one or more metal effect layers further include a transparent or translucent top coating layer applied to the top surface of the one or more base coating paint layers, the top coating layer protecting and enhancing the metal effect of the one or more metal effect layers Order.

In some embodiments, at least one of the primer layer and the top coating layer comprises metal particles to further enhance the metal effect of the one or more metal effect layers. In some embodiments, the top coating layer is at least one of tinted and colored to further enhance the metallic effect of the one or more metal effect layers.

In some embodiments, the trim is an optionally illuminable trim further comprising a light source arranged below the lower surface of the substrate, the light source through one or more openings defined by the opaque layer, the substrate, and one or more metal effect layers. It is configured to output light. In some embodiments, the trim further comprises a light guide arranged between (i) the light source and (ii) the opaque layer and the bottom surface of the substrate, the light guide being configured to distribute light output from the light source.

According to another aspect of the invention, a method of manufacturing a trim for an object is provided. In one exemplary embodiment, the method comprises providing a transparent or translucent substrate defining an upper surface and a lower surface, applying an opaque layer to one of the upper surface of the substrate and the lower surface of the substrate-the opaque layer is Defining one or more openings through which light can pass-and (i) the top surface of the opaque layer when the opaque layer is applied to the top surface of the substrate and (ii) the top of the substrate when the opaque layer is applied to the bottom surface of the substrate Applying one or more translucent metal effect layers to one of the surfaces.

In some embodiments, applying one or more metal effect layers includes applying one or more layers of metal effect paint. In another embodiment, applying one or more metal effect layers includes digitally printing one or more layers of metal effect materials. In some embodiments, the one or more metal effect layers include only one or more base coating layers of metal effect paint.

In some embodiments, applying one or more metal effect layers comprises (i) applying a translucent primer layer applied to a portion of the substrate corresponding to the top surface and one or more openings of the opaque layer and (ii) the top of the primer layer And applying a layer of at least one translucent base coating paint of metal effect paint applied to the surface. In some embodiments, the method further comprises applying a transparent or translucent top coating layer to the top surface of the one or more base coating paint layers, the top coating layer protecting and enhancing the metal effect of the one or more metal effect layers Order.

In some embodiments, applying the opaque layer includes applying an initial opaque layer that does not define one or more openings, and removing a portion of the initial opaque layer corresponding to the one or more openings to obtain an opaque layer. Includes additionally. In some embodiments, applying the initial opaque layer includes spraying the opaque primer and curing the sprayed opaque primer to obtain an initial opaque layer, and removing a portion of the initial opaque layer includes removing the initial opaque layer And laser etching the layer.

In some embodiments, applying the opaque layer comprises applying a temporary mask layer to the one of the upper surface of the substrate and the lower surface of the substrate, the temporary mask layer and the one of the upper surface of the substrate and the lower surface of the substrate The method further comprises applying an initial opaque layer by spraying an opaque primer over it, and removing the temporary mask layer and a portion of the initial opaque layer associated therewith to obtain an opaque layer. In another embodiment, applying the opaque layer includes digitally printing the opaque material to a portion of the top surface of the substrate.

In some embodiments, the method further includes injection or compression molding, thermoforming, or additive manufacturing of the plastic material to form the substrate. In some embodiments, the trim is a selectively illuminable trim, and the method comprises the steps of arranging the light source below the lower surface of the substrate, wherein the light source is a substrate, one or more openings defined by an opaque layer, and one or more metal effect layers Configured to output light through-and packaging the light source and optionally illuminable trim into a single integrated module.

According to another aspect of the invention, a method of manufacturing a trim for an object is provided. In one exemplary embodiment, the method includes providing a transparent or translucent substrate defining an upper surface, applying an opaque layer to the upper surface of the substrate, wherein the opaque layer opens one or more openings through which light can pass. Limited-and applying at least one translucent metal effect layer to the top surface of the opaque layer.

In some embodiments, applying one or more metal effect layers includes applying one or more layers of metal effect paint. In another embodiment, applying one or more metal effect layers includes digitally printing one or more layers of metal effect materials.

In some embodiments, the one or more metal effect layers include only one or more base coating layers of metal effect paint. In another embodiment, applying one or more metal effect layers comprises (i) applying a translucent primer layer applied to a portion of the substrate corresponding to the top surface and one or more openings of the opaque layer and (ii) the top of the primer layer And applying a layer of at least one translucent base coating paint of metal effect paint applied to the surface. In some embodiments, the method further comprises applying a transparent or translucent top coating layer to the top surface of the one or more base coating paint layers, the top coating layer protecting and enhancing the metal effect of the one or more metal effect layers Order.

In some embodiments, applying the opaque layer includes applying an initial opaque layer that does not define one or more openings, and removing a portion of the initial opaque layer corresponding to the one or more openings to obtain an opaque layer. Includes additionally. In some embodiments, applying the initial opaque layer includes spraying the opaque primer and curing the sprayed opaque primer to obtain an initial opaque layer. In some embodiments, removing a portion of the initial opaque layer includes laser etching the initial opaque layer. In another embodiment, applying the opaque layer 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 and the temporary mask layer of the substrate, and temporary The method further includes removing the mask layer and a portion of the initial opaque layer associated therewith to obtain an opaque layer. In another embodiment, applying the opaque layer includes digitally printing the opaque material to a portion of the top surface of the substrate.

In some embodiments, the method further includes injection or compression molding, thermoforming, or additive manufacturing of the plastic material to form the substrate.

In some embodiments, the trim is an selectively illuminable trim, and the method further comprises arranging the light source under the lower surface of the substrate, the light source comprising: a substrate, one or more openings defined by an opaque layer, and And configured to output light through one or more metal effect layers. In some embodiments, the method further includes arranging the light guide between the light source and the bottom surface of the substrate, the light guide being configured to distribute light output from the light source. In some embodiments, the method further includes packaging the light source and optionally illuminable trim into a single integrated module.

According to another aspect of the invention, a method of manufacturing a trim for an object is provided. In one exemplary embodiment, the method comprises providing a transparent or translucent substrate defining an upper surface and a lower surface, applying an opaque layer to the lower surface of the substrate, wherein the opaque layer is one through which light can pass Limiting the openings above, and applying one or more translucent metal effect layers to the top surface of the substrate.

In some embodiments, applying one or more metal effect layers includes applying one or more layers of metal effect paint. In another embodiment, applying one or more metal effect layers includes digitally printing one or more layers of metal effect materials.

In some embodiments, the one or more metal effect layers include only one or more base coating layers of metal effect paint. In another embodiment, applying one or more metal effect layers comprises: (i) applying a translucent primer layer applied to the top surface of the substrate and (ii) one or more translucent bases of metal effect paint applied to the top surface of the primer layer. And applying a coating paint layer. In some embodiments, the method further comprises applying a transparent or translucent top coating layer to the top surface of the one or more base coating paint layers, the top coating layer protecting and enhancing the metal effect of the one or more metal effect layers Order.

In some embodiments, applying the opaque layer includes applying an initial opaque layer that does not define one or more openings, and removing a portion of the initial opaque layer corresponding to the one or more openings to obtain an opaque layer. Includes additionally. In some embodiments, applying the initial opaque layer includes spraying the opaque primer and curing the sprayed opaque primer to obtain an initial opaque layer. In some embodiments, removing a portion of the initial opaque layer includes laser etching the initial opaque layer. In another embodiment, applying the opaque layer comprises applying a temporary mask layer to the lower surface of the substrate, applying an initial opaque layer by spraying an opaque primer over the lower surface of the substrate and the temporary mask layer, and temporary The method further includes removing the mask layer and a portion of the initial opaque layer associated therewith to obtain an opaque layer. In another embodiment, applying the opaque layer includes digitally printing the opaque material to a portion of the top surface of the substrate.

In some embodiments, the method further includes injection or compression molding, thermoforming, or additive manufacturing of the plastic material to form the substrate.

In some embodiments, the trim is an selectively illuminable trim, and the method further comprises arranging the light source under the lower surface of the substrate, the light source comprising: a substrate, one or more openings defined by an opaque layer, and And configured to output light through one or more metal effect layers. In some embodiments, the method further includes arranging the light guide between the light source and the bottom surface of the substrate, the light guide being configured to distribute light output from the light source. In some embodiments, the method further includes packaging the light source and optionally illuminable trim into a single integrated module.

Further areas of applicability of the teachings of the present invention will become apparent from the detailed description, claims and drawings provided below, where like reference numerals refer to like features throughout the several views of the drawings. It is to be understood that the detailed description, including the disclosed embodiments, and the drawings referred to therein is merely illustrative in nature, intended for purposes of illustration only, and is not intended to limit the scope of the invention, its application or use. Accordingly, it is intended that modifications that do not depart from the gist of the present invention are within the scope of the present invention.

1A and 1B are cross-sectional views of a first embodiment of a selectively illuminable trim according to the principles of the present invention for two different user viewing angles.
2 is a flow diagram of a method of manufacturing a first embodiment of a selectively illuminable trim according to the principles of the present invention.
3A and 3B are cross-sectional views of a second embodiment of a selectively illuminable trim according to the principles of the present invention for two different user viewing angles.
4A and 4B are cross-sectional views of alternative first and second embodiments of selectively illuminable trims in accordance with the principles of the present invention.
5 is a flow diagram of a method of manufacturing a second embodiment of a selectively illuminable trim according to the principles of the present invention.

As discussed above, chromium plating is formed of one or more opaque metal layers that do not allow light to pass through, making them unusable for decorative trims with backlighting effects. Chrome plating also weakens radar transmission. Accordingly, improved trims that appear to be selectively illuminable metals and methods of making them are presented. In another aspect of the invention, a metal-looking trim comprising multiple stacked layers with a light source and an optional light guide are packaged together to form a single integrated module. In some embodiments, these trims utilize metallic effect paint and an opaque rear layer to achieve components that appear aesthetically pleasing metal as chrome plating. In another embodiment, this trim utilizes digital printing to deposit or apply a metal effect layer instead of a metal effect paint. In a further embodiment, a non-metal effect paint can be utilized instead of a metal effect paint. For example, a matte finish paint can be utilized. Traditional painting techniques (eg, rolls, brushes, or sprays) can be used to apply metallic or non-metallic effect paints. Moreover, vacuum deposition or static electricity (eg, powder coating) can be used to apply metallic or non-metallic paint. In each embodiment, multiple application techniques can be used. For example, an opaque rear layer can be applied by spraying.

In the first embodiment, an opaque layer is deposited on the top surface of the substrate, thereby placing it closer to the viewing user's eye, and having less distortion, for example when viewed from an angle Create a more distinct image. In a second embodiment, an opaque layer is deposited on the lower surface of the substrate, thereby placing it further away from the eye of the user observing it, and potentially less with greater distortion, for example when viewed at an angle Produces a distinct image. However, this second embodiment has an advantage from a processing point of view, since the opaque layer only needs to have the required level of adhesion to the lower surface of the substrate. This processing advantage can lead to reduced costs, which can be more than offset any potential distortion in observation. Moreover, the amount of distortion depends on the thickness of the substrate and the type of light source. Different levels of distortion can be considered acceptable for different applications.

Referring now to FIGS. 1A and 1B, a cross-sectional view of a first embodiment of a single integrated module 100 is shown. The module 100 includes a trim stack 104 that looks like a metal formed from multiple stacked layers. A transparent or translucent substrate 108 forms the base of the trim 104. Details of the formation of the substrate 108 are described in detail below with reference to FIG. 2. Non-limiting examples of the substrate 108 are plastic or polymeric materials such as polycarbonate (PC), polymethyl methacrylate (PMMA), acrylonitrile butadiene styrene (ABS), styrene acrylic, styrene acrylonitrile Polymers, polyamides, and combinations thereof. For vehicle trim applications, the substrate 108 may be an internal component (instrument panel assembly, central console assembly, multimedia or infotainment unit assembly, door trim panel, etc.) or external bodywork component (front or side grille assembly, bumper or It can be a fender accent, a head or taillight highlight, a trunk lid finish, etc.). It will be appreciated that the systems and methods described herein are not limited to automotive applications, but may be applicable to decorative trim for non-automotive applications (home appliances and consumer goods, railways, motorbikes, aerospace, etc.).

An opaque layer 112 is applied to the top surface of the substrate 108. Details of the application of the opaque layer 112 are described in detail below with reference to FIG. 2. The opaque layer 112, although shown as a black primer layer, can have any suitable color or composition that prevents or substantially mitigates light transmission therethrough. Non-limiting examples of the opaque layer 112 include epoxy-based, polyurethane-based, and acrylic-based curable wet paints having opaque colored pigments, and combinations thereof. The opaque layer 112 may alternatively be digitally printed. The opaque layer 112 defines one or more gaps or openings 116 through which light can pass. The one or more openings 116 correspond to designed lighting highlight effects, such as highlights, logos, signs, icons, motifs, patterns, buttons, or other similar highlights to objects associated with trim. The translucent primer layer 120 is selectively applied to the top surface of the opaque layer 112 as well as the top surface of the substrate 108 within regions corresponding to the one or more openings 116. Details of the application of the primer layer 120 are described in detail below with reference to FIG. 2. Non-limiting examples of primer layer 120 include transparent or translucent epoxy, polyurethane, and acrylic curable wet paints and combinations thereof.

A portion of the substrate 108 and at least one translucent metal effect layer 124 on the top surface of the base coating layer 120 (or in areas corresponding to the one or more openings 116 if the primer layer 120 is not applied) and Opaque layer 112). For example, two or more paint layers (base coating layer 120 + single metal effect paint layer 124), single primer layer 120 + two metal effect paint layers 124, 2 without primer layer 120 Dogs metal effect paint layer 124, etc.) can achieve an optimal aesthetic. Alternatively, the metal effect layer (s) 124 can be applied via digital printing. Details of the application of the metal effect layer 124 are described in detail below with reference to FIG. 2. The metal effect layer 124 is translucent (ie, but is not limited to, transition metals, post-transition metals, metalloids, and combinations thereof (eg, alloys such as oxides and oxide alloys)). It is translucent because it is formed of a paint or printed material comprising an element that is at least partially light transmissive. For example, the metal effect paint can be a paint solution comprising flakes of one or more of the elements described above. It will be appreciated that metal flakes or similar materials can also be included in the primer layer 120 to further enhance the metal effect.

The thickness of the metal effect paint layer 124 should be such that it remains at least translucent when illuminated by a backlight, while also being rendered metallic when not illuminated. The translucency of the metallic layer can also be affected by the chemical composition of the layer and the dispersion of the elements when reflected. The metal effect paint layer 124 may also include a single metal effect paint or multiple layers of different metal effect paints applied at various stages to achieve the desired appearance and translucency (ie, desired optical properties). For example, FIG. 4A shows a single metal effect layer 124 of one or more base coating layers of metal effect paint (without primer layer 120), with an optional top coating layer 128 to achieve optimal aesthetics. ), Which saves money and reduces complexity-shows one configuration 400 of the trim stack 104. As discussed above, digital printing can be utilized as an alternative to metallic effect paint. Specifically, one or more metal effect layers can be digitally printed on the substrate 108, thereby eliminating the need for a primer layer 120.

An optional top coating layer 128 can be applied to the top surface of the metal effect layer 124. Details of the application of the optional top coating layer 128 are described in detail below with reference to FIG. 2. Non-limiting examples of the top coating layer 128 include transparent or translucent epoxy-based, polyurethane-based, and acrylic curable wet paints and combinations thereof. The optional top coating layer 128 protects the metal effect layer 124 (eg, from being scraped, peeled, or scratched) and / or the appearance of the metal effect layer 124 (eg, its (By improving the gloss appearance). It will be appreciated that the top coating layer 128 may further enhance the metallic effect by including metallic flakes or similar materials. It will also be appreciated that the top coating layer 128 may be tinted and / or colored to further enhance the metallic effect. Non-limiting examples of this include blue metal effect, copper metal effect, and bronze metal effect, but any color tone and / or color combination may be utilized.

Although the various top layers 112, 120, 124, and 128 are shown as having approximately the same thickness, their actual thickness can be varied and, in most cases, substantially thinner than the thickness of the substrate 108. Will understand. In one exemplary embodiment, the primer layer 120 may be 15 micrometers thick, the metal effect layer 124 may be 1 to 3 micrometers thick, and the top coating layer 128 may be 20 thick. To 22 micrometers. It is much thinner compared to a standard paint process with a primer layer thickness of 20 to 25 micrometers, a base coating paint layer thickness of 12 to 16 micrometers, and a top coating layer thickness of 30 to 35 micrometers. In another exemplary embodiment, the primer layer 120 can be 3 to 30 micrometers thick, the metal effect layer 124 can be 1 to 6 micrometers thick, and the top coating layer 128 is thick. May be from 10 to 50 micrometers. In this example, metal effect paint layer 124 still has a substantially thinner thickness than conventional paint processes.

A single integrated module 100 is generated from a light source 132 (eg, light emitting diode (LED), organic LED (OLED), optical fiber, electroluminescent, or similar device, such as a laser light source) and light source 132 It further includes an optional light guide 136 for directing, focusing, or distributing light through the substrate 108 and the one or more openings 116 to form a visible field 140. The reference 144 represents the focus or viewing angle of the viewing user. As shown in FIG. 1A, there is no distortion of the visible field 140 from the viewing angle viewed straight. 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. 1B, from an offset or inclined viewing angle, there is very little 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. Thus, the viewing user 144 will still see a clear and sharp image as intended when illuminated by the backlight by the light source 132, and a glossy, metallic visible layer when not illuminated by the backlight by the light source 132 Will see

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 and 1B is shown. At 204, a transparent or translucent substrate is obtained. Substrate 108 uses any suitable plastic or polymer processing technique, including, but not limited to, injection molding, extrusion, compression molding, thermoforming, and additive manufacturing (eg, three-dimensional (3D) printing), for example. Can be formed. As mentioned above, non-limiting examples of the substrate 108 include plastic or polymer materials such as PC, PMMA, ABS, styrene acrylic, styrene acrylonitrile polymer, polyamide, and combinations thereof. In one exemplary embodiment, the substrate is a plastic inner component or outer body component of a vehicle as described herein above.

At 208, an opaque layer 112 is applied to the top surface of the substrate 108. In one exemplary embodiment, the opaque layer 112 is applied by spraying an opaque primer, which is then cured to form an initial opaque layer. Subsequently, a portion of the initial opaque layer corresponding to the one or more openings is removed (eg, peeled off) to obtain an opaque layer. For example, laser etching can be utilized to remove 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 one or more openings 116 defined by the opaque layer 112. This temporary mask layer can be a tape or other adhesive or 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 a portion of the initial opaque layer corresponding to the one or more openings 116 to obtain the opaque layer 112. As mentioned above, non-limiting examples of the opaque layer 112 include epoxy-based, polyurethane-based, and acrylic-based curable wet paints having opaque colored pigments, and combinations thereof. In another exemplary embodiment, the opaque layer 112 is an opaque paint that is deposited using a digital printing process, whereby (i) a subsequent laser etch process to define one or more openings 116, or (ii) Avoiding the need to use a mask, avoid depositing the opaque layer 112 and forming one or more openings 116.

At optional 212, the translucent primer layer 120 is applied to the substrate 108 in the region corresponding to one or more openings 116 defined by the opaque layer 112 and to the top surface of the opaque layer 112. The application of the primer layer 120 allows him to define a substantially flat or planar upper surface (e.g., the same height), while being thicker in areas that are non-uniform (i.e., corresponding to one or more openings 116). It should also have a thickness (less thick in other areas). In one exemplary embodiment, primer layer 120 is applied by spraying a translucent coating, which is then cured to form primer layer 120. As previously mentioned, non-limiting examples of primer layer 120 include transparent or translucent epoxy-based, polyurethane-based, and acrylic-based curable wet paints and combinations thereof.

At 216, a translucent metal effect layer 124 is applied to the top surface of the base coating layer 120. The metal effect layer 124 may be any suitable painting or printing process, such as, but not limited to, spraying, brushing, rolling, and digital printing, as well as physical vapor deposition (PVD) and chemical vapor deposition (CVD) or electrostatic deposition ( Vacuum coating, for example). As mentioned previously, the paint solution is translucent (ie, but not limited to, transition metals, post-transition metals, metalloids, and combinations thereof (e.g., alloys such as oxides and oxide alloys)). Elements that are at least partially light transmissive). For example, the metal effect paint solution may include flakes of one or more of the elements described above. As previously mentioned, the thickness of the metal effect paint layer 124 should be such that it remains at least translucent when illuminated by a backlight, while also being rendered metallic when not illuminated. It will also be understood that multiple layers of a single metal effect paint or multiple layers of different metal effect paints can be applied in different steps to form a metal effect paint layer 124.

At optional 220, an optional transparent or translucent top coating layer 128 is applied to the top surface of the metal effect layer 124. Similar to the primer layer 120, in one exemplary embodiment, the top coating layer 128 is applied by spraying a transparent or translucent coating, which is then cured to form the top coating layer 128. As mentioned above, non-limiting examples of the top coating layer 128 include transparent or translucent epoxy-based, polyurethane-based, and acrylic-based curable wet paints and combinations thereof. A potential advantage of providing the top coating layer 128 is to protect the metal effect layer 124 from weathering or damage (shaving, scratching, etc.) and / or the appearance of the metal effect layer 124 (e.g., Gloss). At optional 224, light source 132 and optional light guide 136 are arranged below the lower surface of substrate 108. At optional 228, trim stack 104 and light source 132 (and, optionally, light guide 136) are assembled or packaged into a single integrated module 100. The method 200 then ends.

Referring now to FIGS. 3A and 3B, a cross-sectional view of a second embodiment of a single integrated module 300 is shown. The module 300 includes a trim stack 304 that looks like a metal formed of multiple stacked layers. The trim stack 304 includes a transparent or translucent substrate 308 having an opaque layer 312 applied to the bottom surface of the substrate 308, where the opaque layer 312 defines one or more openings 316. The trim stack 304 further includes an optional translucent primer layer 320 applied sequentially to the top surface of the substrate 308, a translucent metal effect layer 324, and an optional transparent or translucent top coating layer 328 do. For example, FIG. 4B requires only a single metal effect layer 324 (without primer layer 320), with an optional top coating layer 328 to achieve optimal aesthetics-thereby costing Saves and reduces complexity-shows one configuration 450 of the trim stack 304. It will be understood that these layers 308-328 may be applied or formed of the same or similar materials as described above with reference to layers 108-128 of FIGS. 1A and 1B and using the same or similar methods. The light source 332 and the optional light guide 336 are the same as the relevant descriptions of the light source 132 and the optional light guide 136.

Although the various top layers 312, 320, 324, and 328 are shown as having approximately the same thickness, their actual thickness can be varied and, in most cases, substantially thinner than the thickness of the substrate 308. Will understand. In one exemplary embodiment, the primer layer 320 can be 15 micrometers thick, the metal effect layer 324 can be 1 to 3 micrometers thick, and the top coating layer 328 is 20 thick. To 22 micrometers. It is much thinner compared to a standard paint process with a primer layer thickness of 20 to 25 micrometers, a base coating paint layer thickness of 12 to 16 micrometers, and a top coating layer thickness of 30 to 35 micrometers. In another exemplary embodiment, the primer layer 320 can be 3 to 30 micrometers thick, the metal effect layer 324 can be 1 to 6 micrometers thick, and the top coating layer 328 is thick. May be from 10 to 50 micrometers. In this example, the metal effect paint layer 324 still has a substantially thinner thickness than conventional paint processes. As discussed above, digital printing can be utilized as an alternative to metallic effect paint. Specifically, one or more metal effect layers can be digitally printed on the substrate 308, thereby eliminating the need for a primer layer 320.

The main difference between module 100 and module 300 is that an opaque layer 312 is applied to the lower surface of substrate 308 in module 300. An optional transparent or translucent lower coating layer 318 applied to the lower surface of the substrate 308 in areas corresponding to the one or more openings 316 is also present such that the lower surface (B side) of the trim stack 304 is the same. It can be made high. This lower coating layer 318 can be the same or similar material as the optional primer layer 320 and / or the optional upper coating layer 328, and can be applied using the same or a similar process (eg, masking). You can. As shown in FIG. 3A, there is no distortion of the visible field 340 from the viewing angle viewed directly (see reference 344 representing the observing user 344). 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.

However, as shown in Fig. 3B, from an offset or inclined 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 greater than the actual width of the visible field 340. Thus, the viewing user 144 will see a less pronounced (i.e. slightly distorted) image when illuminated by the backlight by the light source 332, while glossiness when not illuminated by the backlight by the light source 332, You will see a layer that looks like metal. However, one advantage of the configuration of the module 300 is that it is easier to process or form. More specifically, the opaque layer 312 need only be designed or selected for adhesion to the substrate 308, not to both the substrate 308 and the primer layer 320 (which are shown in FIGS. 1A and 1B). As required for the opaque layer 112 for the substrate 108 and base coating layer 120).

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

At optional 512, a primer layer 320 is applied to the top surface of the substrate 308. At 516, the metal effect layer 324 is not only conventional means (eg, spraying, brushing, rolling, and digital printing), but also physical vapor deposition (PVD) and chemical vapor deposition (CVD) or electrostatic deposition (eg, powder coating) ) Is applied to the top surface of the primer layer 320 using a vacuum process such as. At optional 520, top coating layer 328 is applied to the top surface of metal effect layer 324. At optional 524, light source 332 and optional light guide 336 are arranged below the lower surface of trim stack 304. At optional 428, trim stack 304 and light source 332 (and, optionally, light guide 336) are assembled or packaged into a single integrated module 300. The method 500 then ends.

Exemplary embodiments are provided to make the present invention thorough and will fully convey the scope to those skilled in the art. To provide a thorough understanding of embodiments of the present invention, a number of specific details are presented, such as examples of specific components, devices, and methods. It will be apparent to those skilled in the art that certain details need not be employed, such exemplary embodiments can be implemented in many different forms, and none should be construed as limiting the scope of the invention. In some exemplary embodiments, known procedures, known device structures, and known techniques are not described in detail.

The terms used in this specification are only for describing specific exemplary embodiments and are not intended to be limiting. As used herein, singular (“a”, “an” and “the”) may be intended to also include plural forms unless the context clearly dictates otherwise. The term “and / or” includes any and all combinations of one or more of the listed related items. The terms "comprises", "comprising", "having" and "having" are inclusive, thus specifying the presence of the mentioned features, entities, steps, operations, elements, and / or components, It does not exclude the presence or addition of one or more other features, completeness, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and acts described herein should not be construed as necessarily requiring their performance in the specific order discussed or illustrated, unless specifically identified as a sequence of performance. It will also be understood that additional or alternative steps may be employed.

Although the terms first, second, third, etc. can be used herein to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections may be It should not be limited by terms. These terms can only be used to distinguish one element, component, region, layer or section from another region, layer or section. As used herein, terms such as “first”, “second” and other numerical terms do not imply order or order unless clearly indicated by context. Thus, a first element, component, region, layer or section discussed below may be referred to as a second element, component, region, layer or section without departing from the teachings of the exemplary embodiments.

The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to cover or limit the invention. The individual elements or features of a particular embodiment are largely not limited to that particular embodiment and, where applicable, may be used interchangeably and in selected embodiments, although not specifically shown or described. The same can also be changed in many ways. Such modifications should not be regarded as a departure from the present invention, and all such modifications are intended to be included within the scope of the present invention.

Mixing and matching of features, elements, methods, and / or functions between various examples will allow those skilled in the art that features, elements and / or functions of one example may be appropriately incorporated into other examples, unless otherwise described above. It should be understood that can be clearly considered in this specification to be understood from this teaching.

Claims (30)

As a trim for an object,
A transparent or translucent substrate defining an upper surface;
An opaque layer applied to the top surface of the substrate, the opaque layer defining one or more openings through which light can pass; And
And one or more translucent metal effect layers applied to the top surface of the opaque layer. The trim of claim 1, wherein the at least one metal effect layer comprises at least one metal effect paint layer. The trim of claim 1, wherein the at least one metal effect layer comprises at least one digitally printed metal effect material layer. The trim of claim 2, wherein the one or more metal effect layers comprises only one or more base coating layers of metal effect paint. The method of claim 2, wherein the at least one metal effect layer comprises (i) a translucent primer layer applied to a portion of the substrate corresponding to the top surface of the opaque layer and the at least one opening and (ii) the primer layer. Trim comprising at least one translucent base coating paint layer of metal effect paint applied to the top surface. The method of claim 4 or 5, wherein the one or more metal effect layers further comprises a transparent or translucent top coating layer applied to the top surface of the one or more base coating paint layers, the top coating layer being the one or more metals. Trim, protecting and enhancing the metallic effect of the effect layer. The method of claim 6, wherein at least one of the primer layer and the top coating layer comprises (i) metal particles to further enhance the metal effect of the one or more metal effect layers and (ii) the one or more metals. Trim, which is at least one of tinted and tinted to further enhance the metallic effect of the effect layer. 8. The trim according to claim 1, wherein the trim is a selectively illuminable trim further comprising a light source arranged below the lower surface of the substrate, the light source being by the substrate, the opaque layer. And configured to output light through the defined one or more openings, and the one or more metal effect layers. 9. The trim of claim 8, further comprising a light guide body arranged between the light source and the lower surface of the substrate, the light guide body being configured to distribute light output from the light source. As a trim for the object,
A transparent or translucent substrate defining an upper surface and a lower surface;
An opaque layer applied to the lower surface of the substrate, the opaque layer defining one or more openings through which light can pass; And
And one or more translucent metal effect layers applied to the top surface of the substrate. The trim of claim 10, wherein the one or more metal effect layers comprises one or more metal effect paint layers. The trim of claim 10, wherein the one or more metal effect layers comprises one or more layers of digitally printed metal effect materials. 12. The trim of claim 11, wherein the one or more metal effect layers comprise only one or more base coating layers of metal effect paint. 14. The method of claim 13, wherein the one or more metal effect layers comprises (i) a translucent primer layer applied to the top surface of the substrate and (ii) one or more translucent base coating paint layers of metal effect paint applied to the top surface of the primer layer. Included, trim. 15. The method of claim 13 or claim 14, wherein the at least one metal effect layer further comprises a transparent or translucent top coating layer applied to the top surface of the at least one base coating paint layer, the top coating layer is the at least one metal Trim, protecting and enhancing the metallic effect of the effect layer. 16. The method of claim 15, wherein at least one of the primer layer and the top coating layer comprises (i) metal particles to further enhance the metal effect of the one or more metal effect layers and (ii) the one or more metals Trim, which is at least one of tinted and tinted to further enhance the metallic effect of the effect layer. 17. The trim according to any one of claims 10 to 16, wherein the trim is an optionally illuminable trim further comprising a light source arranged below the lower surface of the substrate, the light source being defined by the opaque layer. And configured to output light through one or more openings, the substrate, and the one or more metal effect layers. 18. The method of claim 17, further comprising (i) a light guide arranged between the light source and (ii) the opaque layer and the bottom surface of the substrate, the light guide configured to distribute light output from the light source Being, trim. A method of manufacturing a trim for an object,
Providing a transparent or translucent substrate defining an upper surface and a lower surface;
Applying an opaque layer to one of the upper surface of the substrate and the lower surface of the substrate, wherein the opaque layer defines one or more openings through which light can pass; And
One or more translucent metal effects on (i) the top surface of the opaque layer when the opaque layer is applied to the top surface of the substrate and (ii) one of the top surfaces of the substrate when the opaque layer is applied to the bottom surface of the substrate A method comprising applying a layer. 20. The method of claim 19, wherein applying the one or more metal effect layers comprises applying one or more layers of metal effect paint. 20. The method of claim 19, wherein applying the one or more metal effect layers comprises digitally printing one or more layers of metal effect materials. The method of claim 21, wherein the one or more metal effect layers comprises only one or more base coating layers of metal effect paint. 23. The method of claim 22, wherein applying the one or more metal effect layers comprises: (i) applying a translucent primer layer applied to a portion of the substrate corresponding to the top surface of the opaque layer and the one or more openings, and (ii) ) Applying at least one translucent base coating paint layer of metal effect paint applied to the top surface of the primer layer. 24. The method of claim 22 or 23, further comprising applying a transparent or translucent top coating layer to the top surface of the one or more base coating paint layers, wherein the top coating layer is a metal of the one or more metal effect layers. How to protect and enhance the effectiveness. 25. The method of any of claims 19-24, wherein applying the opaque layer comprises:
Applying an initial opaque layer that does not define the one or more openings; And
And removing a portion of the initial opaque layer corresponding to the one or more openings to 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, removing a portion of the initial opaque layer The method comprising laser etching the initial opaque layer. 25. The method of any of claims 19-24, wherein applying the opaque layer comprises:
Applying a temporary mask layer to the one of the upper surface of the substrate and the lower surface of the substrate;
Applying an initial opaque layer by spraying an opaque primer over the temporary mask layer and one of the upper surface of the substrate and the lower surface of the substrate; And
And removing the temporary mask layer and a portion of the initial opaque layer associated therewith to obtain the opaque layer. 25. The method of any one of claims 19 to 24, wherein applying the opaque layer comprises digitally printing an opaque material to a portion of the top surface of the substrate. 29. The method of any one of claims 19 to 28, further comprising injection or compression molding, thermoforming, or additive manufacturing of a plastic material to form the substrate. 30. The method of any one of claims 19-29, wherein the trim is a selectively illuminable trim, the method comprising:
Arranging a light source under the lower surface of the substrate, the light source being configured to output light through the substrate, the one or more openings defined by the opaque layer, and the one or more metal effect layers; And
Further comprising packaging the light source and the selectively illuminable trim in a single integrated module.

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