WO2009063048A1

WO2009063048A1 - Piano lacquer appearance through use of films

Info

Publication number: WO2009063048A1
Application number: PCT/EP2008/065552
Authority: WO
Inventors: Henry Müller; Klaus Specht; Christian Heigl
Original assignee: Lisa Dräxlmaier GmbH
Priority date: 2007-11-15
Filing date: 2008-11-14
Publication date: 2009-05-22
Also published as: DE102007054579B4; DE102007054579A1

Abstract

The invention relates to a decorative material with piano lacquer appearance, especially for use in and on motor vehicles, with a total thickness of at least 0.5 mm, consisting of a film composite comprising at least one film of a glass-clear material arranged on the visible side of the decorative material and at least one film, arranged below said film, of a pigmented material or of a material admixed with soluble colorant. The invention further relates to a process for producing a decorative material with piano lacquer appearance, especially for use in and on motor vehicles, with a total thickness of at least 0.5 mm, consisting of a film composite, comprising the provision of at least one film of a glass-clear material for arrangement on the visible side of a decorative material carrier, and the arrangement of at least one film of a pigmented material or of a material admixed with soluble colorant below the film of glass-clear material.

Description

Piano lacquer optic dtarch foil insert

Field of the invention

The invention relates to a decorative material with piano finish, as it finds in particular for use in and on motor vehicles application, and a method for its preparation.

State of the art

As a piano varnish or varnish usually paint compounds are called, on the one hand provide a homogeneous, opaque and smooth surface and on the other hand achieve a special shine and a special depth effect. Such paint compounds give a particularly exclusive impression of the surface and are common, for example, in pianos themselves, high-quality speakers or furniture.

The special depth effect of the piano lacquer is achieved by the observer looking at a surface, without recognizing the actual "reason" of the lacquer, which is achieved by the lacquer layer having a sufficient depth, and by a usually steadily growing surface Pigmentation up to a pigment density that no longer allows looking through to the "bottom" of the decorative material. The production of such piano lacquers or grinding lacquers is extremely complicated. Usually, piano lacquer trim parts are produced by repeated painting with at least 5 and in some cases more than 8 layers. Here, the individual layers are applied by spraying on the surface, dried (annealed), sanded and repainted. Depending on the layer, different colored or pigmented lacquers are used. Finally, the piano lacquer layer is sanded and polished after the curing of all lacquer layers to obtain a smooth surface with a brilliant appearance.

To this elaborate and costly

To circumvent manufacturing processes, attempts have been made to recreate the piano finish by a two-component injection molding, in which a smooth, usually black carrier injection-molded and over-injected with a highly transparent plastic on its top side. However, unlike the original piano lacquer look, the viewer sees the surface of the carrier plastic, so that the special depth effect of the piano lacquer can only be achieved or adjusted inadequately.

Multilayer films with special optical effects and processes for their production are known from the prior art. For example, EP 1 728 624 A1 describes a multilayer film having at least one color layer and at least one effect layer. In this case, the optical special effects are achieved by the contrast of the color pigments with the effect pigments. The multilayer film is obtained by coextrusion of the at least one color layer and the at least one effect layer.

Similarly, US 6,998,084 B2 describes a coextruded material of a pigmented and a Transparent film, which can be used for coating, for example, automobile panels. Here, a three-layer structure with effect and color pigments based on transparent plastics is used.

The film composites known from the prior art are capable of achieving special optical effects through the interaction of the optical properties of different coextruded films. A piano finish can not be achieved by these film composites.

Object of the invention

It was therefore an object of the invention to provide a decorative material with piano lacquer optics and a method for its production, which is less expensive and thus less expensive to produce than the prior art. This object of the invention is achieved by a decorative material having the features of claim 1 and a method having the features of claim 10. Advantageous embodiments of the invention are described in the respective dependent claims.

Summary of the invention

For the first time, the invention makes it possible to produce a piano lacquer look solely through the use of a plurality of films to be joined together to form a film composite. The coloring of the films can be done very defined, ie, that in comparison to the injection molding no flow lines and compared to the coating a defined layer thickness can be achieved in all component areas. The invention enables a very good surface and depth brilliance and also allows the production of defined embossed, grained surfaces. Moreover, the decorative material according to the invention can be produced in a single process and does not require intermediate steps with respect to drying or Grinding individual layers. Moreover, the decorative material according to the invention does not have to be reground and / or polished. Rather, the preparation of the piano lacquer layer takes place via a preferably automated, rapid forming process and enables the highest possible reproducibility of the result obtained.

To achieve the piano lacquer optics according to the invention with the corresponding depth effect, a total thickness of at least 0.5 mm of the film composite is required. Moreover, a piano finish will only be achievable with a clear material on the visible side of the decor material.

In general, transparent plastics do not differ significantly in their optical properties from inorganic glasses. In terms of their translucency, plastics are roughly divided into three classes: transparent (transparent), translucent (opaque) and opaque or opaque (opaque). The crystal-clear materials therefore have the highest degree of transmission for light.

The use of polyolefins known from the prior art already for film materials with optical effects (PP, PE, PB, etc.) does not permit high transparency at the minimum mechanical strength values required for such films due to the optical properties of the polyolefins. Likewise, these polyolefins generally have a low heat resistance, which makes, for example, the use as interior trim part of motor vehicles, in which the materials must withstand temperature changes from -30 to over +100 ⁰ C, impossible.

According to a first preferred embodiment of the invention, the clear material of the at least one film arranged on the visible side of the decorative material consists of a material selected from the group consisting of polycarbonate, polymethylmethacrylate, thermoplastic Polyurethane and their copolymers and mixtures. As a result, a material is provided which has a particularly advantageous combination of properties not only in terms of light transmission, but also in terms of UV resistance and scratch resistance. It provides a material that is easily and permanently reshapeable and can represent even the smallest radii of curvature without affecting the overall appearance influencing surface defects.

In a preferred embodiment of the invention, the materials of the film composite according to the invention are selected such that in the case of a substantially three-dimensional shaping of the film composite, i. With degrees of deformation in all three spatial directions, such a dimensional stability is achieved that "tool-dropping" components, ie, components can be produced without the need for waxing of the surface by, for example, polishing due to the particularly advantageous material properties especially in edge areas, as they usually occur in reshaped plastic components with small radii, safely avoided.

In a further preferred embodiment of the invention, the pigmented or mixed with soluble dye material at least one film with a pigmentation or color gradient from the visible side to the side facing away from the visible side of the decorative material. As a result, the special depth effect of the piano lacquer finish is achieved in a particularly simple manner by a defined increase in the pigmentation or the soluble dye in the plan view of the decorative material.

In another, equally preferred embodiment of the invention, the pigmented or soluble However, the sequence of at least two films with different pigmentation or dye usually already described above, the pigmentation or color gradient in the direction from the visible side to the side facing away from the visible side Page of the decorative material to be traced. Likewise, however, any other sequence of layers of different colorants, ie pigmentation or soluble dye and / or different thickness, as well as the use of at least one film having its own pigmentation or color gradient, is encompassed by the inventive concept. In addition, the film composite according to the invention may also comprise any desired sequence of films with and without pigmentation or soluble dyes, provided that it is ensured that the visible side of the decorative material is finally formed with a film of a crystal-clear material.

This creates the possibility to achieve a virtually unlimited variety of variations and corresponding diversity of the optical depth effect through the combination of particularly easy to produce, possibly already available on the market available, film materials.

In general, it is preferred according to the invention that the material is made by introducing a defined amount of pigments or soluble dye and their defined distribution into a crystal-clear or transparent matrix. As a result, the piano finish special depth effect of the decorative material is amplified in a particularly advantageous and simple manner.

The decorative material according to the invention has, as already mentioned above, advantageously mechanical properties that allow a deformation even with partially large degrees of deformation, without this the piano lacquer look at least in Partial areas of the decorative material is adversely affected or even tear the surface or entire parts of the decorative material.

In a preferred embodiment of the invention, the film materials for the film composite according to the invention therefore have an E-modulus of at least 800 MPa. Moreover, the film materials in a further, likewise preferred embodiment of the invention have a yield stress of at least 20 MPa.

The skilled person is already aware of various such plastic materials. Table 1 gives a list of selected characteristic values and optical properties of plastics which are particularly preferred in the embodiment of the invention.

Table 1

The use of such materials allows a high degree of deformation without material damage and adverse effects on the piano finish and also provides the scratch resistance required for the application. In addition, in particular the materials mentioned are suitable for To provide the surfaces with suitable Schutzbeschicht, for example, against the signing of fingerprints. Also, with such materials are generally no chemical interactions with professional

To fear cleaning agents, so that the appearance of the decorative material according to the invention can be sustainably ensured.

The decorative material according to the invention is preferably used on the visible side of decor carriers such as instrument panels, interior linings or at least parts thereof. This can be achieved with simple and inexpensive means a particularly exclusive appearance in the vehicle interior. In addition, the film composite according to the invention offers a high degree of formability and, with the selection of suitable materials, also dimensional stability, so that virtually any shape, even complex geometries, can be provided with the desired piano finish in the manner according to the invention.

In another, equally preferred embodiment of the invention, the decorative material according to the invention, however, finds application to outer linings of vehicles, such as trim or bumpers. Another advantageous location are, for example, borders of taillights, complete side mirror housing or at least parts thereof or the like. In this case, the decorative material according to the invention will usually be applied to a particularly dimensionally stable decor carrier. But also preferred is an application as an adhesive film for applying to parts of the automobile outer skin, such as fenders, doors, hoods or the like. Such adhesive films are widely used, for example, in the corresponding colors on taxis and police emergency vehicles. In a second aspect of the invention, a method for producing a decorative material with piano lacquer optics is provided, wherein after providing at least one film of a clear material for placement on the visible side of a decor carrier, the arrangement of at least one film of a pigmented material below the film crystal clear material takes place. The advantages and effects achieved thereby are analogous to those already described above.

In a preferred embodiment of the invention, a three-dimensional deformation takes place before or after production of the film composite, thus a deformation of the film composite in all three spatial directions.

This deformation takes place in a first alternative embodiment of the invention corresponding to a complementary outer shape of an existing decor carrier in order to make a connection of decorative material and decor carrier particularly simple. In another alternative embodiment of the invention, however, the three-dimensional deformation of the decorative material takes place in order to obtain a substantially dimensionally stable film composite with the already introduced forming. The dimensionally stable, reshaped film composite can then serve as a casting mold for a curing decorative carrier, which can be produced, for example, by injection-molding the reshaped decorative material or by foaming a thermosetting decorative carrier.

In a particularly preferred embodiment of the invention, however, the three-dimensional deformation of the decorative material takes place by means of the high-pressure molding process, by application of the hydro-forming or fluid-forming process or by means of mena presses. In all of the above-mentioned preferred deformation processes, the deformation of the decorative material takes place by interaction with a pressurized medium. This will be a the Pole material provided particularly gentle forming process, in which also the force applied to the individual portions of the decorative material to be reshaped forces are precisely defined adjustable. The result is a highly reproducible forming result with a minimum scrap rate.

In a further embodiment of the invention, the three-dimensional negative or positive deformation of the decorative material takes place with vacuum thermoforming or thermoforming. It is also conceivable to mechanically compress the decorative material with a prefabricated stamp.

_Short Description of the Drawings

The invention will be explained in more detail below with reference to some drawings, wherein these drawings of particularly preferred embodiments of the invention are given for illustrative purposes only and can by no means be used to limit the scope of the invention, which is defined in the appended claims.

1 shows a cross-sectional view of a composite of a decor carrier and a first embodiment of a decorative material according to the invention,

2 shows a cross-sectional view of a composite of a decor carrier with a decorative material according to a second embodiment of the invention,

3 shows a cross-sectional view of a composite of a decor carrier and a decorative material according to a third embodiment, and Fig. 4 shows a cross-sectional view of a composite of a Dektorträger with a decorative material according to a fourth embodiment of the invention.

Ways to carry out the invention

In FIG. 1, above a decorative carrier 3, a decorative material according to the invention is arranged, which is formed from a film composite consisting of five individual layers. On the visible side 5 of the illustrated composite, thus the side facing away from the decor carrier 3 side of the film composite 1, 2, a layer 1 of a clear polycarbonate plastic is arranged. Below the crystal-clear polycarbonate film 1, a sequence of four individual films 2 is arranged with pigmentation rising from the visible side 5 to the decoration carrier 3. All layers 1, 2 have the same thickness in this embodiment.

FIG. 2 shows a composite of decor carrier 3 and decorative material 1, 2, in which, unlike the embodiment shown in FIG. 1, the thickness of the individual films 1, 2 is designed differently. To achieve a particularly pronounced Klavielackroptik a significantly thickened layer 1 of clear material was used and the layers with particularly strong pigmentation or liquid dye in the arranged below the layer 1 foils 2 are significantly reduced in its thickness compared to the imple mentation form shown in Figure 1 ,

FIG. 3 shows a decorative material 1, 2, which consists of a layer 1 of crystal-clear material and a layer 2 arranged directly underneath, with the same pigmentation or liquid ink layer throughout. Between this layer 2 and the decor carrier 3, a final layer 4 printed on the back of the film 2 has been applied in this embodiment in order to be sure avoid that in a plan view of the decorative material 1, 2, 4, the decorative material 3 is still visible.

FIG. 4 shows a fourth embodiment of a decorative material 1, 2 according to the invention applied to a decorative carrier 3. On the visible side 5, a thin film of clear material is arranged, under which a film 2 is realized with a steady pigmentation or color gradients from the visible side 5 to the decor carrier 3 out. In accordance with the invention, the layer of clear material 1 as an integral part of the film 2 can also complete the decorative material 1, 2 according to the invention to the visible side 5.

Claims

claims

1. decorative material with piano finish, in particular for use in and on motor vehicles, with a total thickness of at least 0.5 mm, consisting of a film composite comprising at least one arranged on the visible side of the decorative material film of a crystal-clear material and at least one disposed below this film Film of pigmented or soluble colorant added material.

2. Decor material according to claim 1, characterized in that the crystal-clear material of the at least one film on the visible side consists of a material selected from the group consisting of polycarbonate (PC), polymethylmethacrylate (PMMA), thermoplastic polyurethane (TPU) , Polyethylene terephthalate-amorphous (PET-A), cyclo-olefin copolymer (COC), cellulose acetate (CA), cellulose acetobutyrate (CAB), as well as their copolymers and mixtures.

3. decorative material according to one of the preceding claims, characterized in that the pigmented or offset with soluble colorant material has at least one film with a Pigmentierungs- or color gradients from the visible side to the side facing away from the visible side of the decorative material.

4. decorative material according to one of the preceding claims, characterized in that the material comprises a film composite of at least two films with different pigmentations.

5. decorative material according to one of the preceding claims, characterized in that the pigmented or mixed with soluble colorant material can be produced by introducing a defined amount and by defined distribution of pigments or soluble colorant in a crystal clear, translucent or transparent matrix.

6. decorative material according to one of the preceding claims, characterized in that the film materials have an E-modulus of at least 2000 MPa.

7. decorative material according to one of the preceding claims, characterized in that the film materials have a yield stress of at least 50 MPa.

8. decorative material according to one of the preceding claims, characterized in that the decorative material covers the visible side of decorative supports such as instrument panels, interior trim or parts thereof.

9. decorative material according to one of claims 1 to 7, characterized in that the decorative material

Covered exterior trim such as trim or exterior components such as bumpers, side mirrors, fenders or parts thereof.

10. A method for producing a decorative material with piano finish, in particular for use in and on motor vehicles, having a total thickness of at least 0.5 mm, consisting of a film composite comprising providing at least one film of a glaklaren material for placement on the visible side of a decor carrier and arranging at least one film of a pigmented or soluble colorant material beneath the sheet of clear material.

11. The method according to claim 10, characterized in that the film composite is deformed three-dimensionally.

12. The method according to claim 10, characterized in that the three-dimensional deformation takes place by means of high pressure forming.

13. The method according to claim 10, characterized in that the three-dimensional deformation takes place by means of hydro- or fluid-forming.

14. The method according to claim 10, characterized in that the three-dimensional deformation takes place by means of membrane presses.

15. The method according to claim 10, characterized in that the three-dimensional deformation takes place by means of negative or positive deformation of the decorative material with Vakuumtiefziehen or thermoforming.

16. The method according to claim 10, characterized in that the decorative material is pressed mechanically with a prefabricated stamp.

17. The method according to any one of claims 10 to 16, characterized in that the film composite is preferably connected after the three-dimensional deformation with the decor carrier.

18. The method according to any one of claims 10 to 16, characterized in that the film composite is preferably connected during the three-dimensional deformation with the decor carrier.

19. The method according to any one of claims 11 to 15, characterized in that the three-dimensionally deformed Foil composite is back-injected with a decor carrier material.