Light guide plate integrated decorative panel for vehicle and manufacturing method thereof

Abstract

The present invention relates to a light guide plate integrated decorative panel for a vehicle and a manufacturing method thereof. A light guide plate integrated decorative panel for a vehicle is provided with and includes: in a decorative panel for a vehicle mounted to an interior decoration of a vehicle, a light guide plate configured to diffuse light emitted from a light source; and a base portion formed to surround a periphery and a bottom surface of the light guide plate, wherein side surfaces of the light guide plate are formed in a stepped shape so as to be fixed by the base portion that holds the periphery of the light guide plate.

Description

Technical Field

[0001] The present disclosure relates to a decorative panel used as an interior material of a vehicle and a manufacturing method thereof, and more particularly, to a decorative panel integrated with a light guide plate for a vehicle and a manufacturing method thereof, which allows injecting an inserted light guide plate into the panel. Background Art

[0002] In the vehicle interior, a panel or the like is coupled to a vehicle body to decorate the vehicle interior.

[0003] Recently, in order to provide various lighting effects that enhance the vehicle interior when a passenger is riding, technologies for surface illumination applied to interior decoration have been extended.

[0004] By attaching a surface illumination panel having a structure such as Figure 1 to a common panel or by applying the surface illumination panel to a part of the panel, various lighting effects are provided. The surface illumination panel is mounted on one side of a frame 111 and is coupled to a light source 131 such as an LED lamp to provide a lighting effect. The surface illumination panel includes a light guide plate 121 and a base 122 attached to the rear surface of the light guide plate 121. A diffuser 123 may be applied to the front surface of the light guide plate 121.

[0005] According to the related art, the surface illumination panel is formed by injecting to form the base 122, adhering to the light guide plate 121, and adhering the diffuser 123, and then proceeding to subsequent processes such as attaching a protective film or covering with leather (see Figure 2 ). The base 122, the light guide plate 121, and the diffuser 123 are adhered using an adhesive.

[0006] Meanwhile, for aesthetic reasons, ensuring space, etc., in many cases, the vehicle interior is formed into a curved surface, and after the base 122 is first injected, the light guide plate 121 is attached, resulting in a phenomenon that the adhesion site separates over time.

[0007] Since the base 122 and the light guide plate 121 are manufactured separately and adhered to each other, the state in which the base 122 and the light guide plate 121 are adhered to each other is maintained by an adhesive force, in which the surface illumination panel has been manufactured. However, since the shapes of the bonding surfaces of the separately manufactured base 122 and the light guide plate 121 cannot coincide with each other, a phenomenon occurs in which the adhesion site peels off over time.

[0008] The content described in the background art helps to understand the background of the present disclosure and may include content that is unknown to those skilled in the art to which the present disclosure pertains. Summary of the Invention

[0009] The present disclosure aims to solve the above problems, and an object of the present disclosure is to provide a light guide plate integrated decorative panel for a vehicle and a manufacturing method thereof, which can allow a light guide plate to be injected into the panel, thereby preventing the light guide plate from peeling off.

[0010] A light guide plate integrated decorative panel for a vehicle for achieving the above object according to the present disclosure, in a decorative panel for a vehicle to be installed on an interior decoration of a vehicle, includes: a light guide plate configured to diffuse light emitted from a light source; and a base portion formed to surround a periphery and a bottom surface of the light guide plate, and a side surface of the light guide plate is formed in a stepped shape so as to be fixed by the base portion that holds the periphery of the light guide plate.

[0011] The periphery of the light guide plate is formed in a stepped shape such that a cross-sectional area of the light guide plate becomes wider from a front surface of the light guide plate toward a rear surface of the light guide plate.

[0012] The decorative panel is installed on a door trim of the vehicle.

[0013] The light guide plate and the base portion are formed in the same curved shape.

[0014] Meanwhile, a method for manufacturing a light guide plate integrated decorative panel for a vehicle is provided. The method includes: manufacturing a decorative panel including a light guide plate configured to uniformly diffuse light emitted from a light source and a base portion attached to one side surface of the light guide plate, and the decorative panel is installed inside the vehicle; placing the light guide plate on a bottom surface of an upper mold; closing a lower mold such that a first lower mold and a second lower mold installed to be movable upward and downward below the upper mold rise; a first injection to form a part of the base portion around the light guide plate by injecting a molten resin between the upper mold and the first lower mold; opening the second lower mold to lower the second lower mold such that the second lower mold in contact with the bottom surface of the light guide plate is spaced apart from the bottom surface of the light guide plate; and a second injection to inject a molten resin between the light guide plate and the second lower mold.

[0015] Placing the light guide plate allows a negative pressure to be generated inside an air hole formed through the upper mold, and positions the light guide plate on the bottom surface of the upper mold such that the light guide plate is placed on the bottom surface of the upper mold.

[0016] When closing the lower mold, the first lower mold moves to be spaced apart from the upper mold by an interval corresponding to a thickness of the base portion, and the second lower mold moves to contact the bottom surface of the light guide plate.

[0017] An area of an upper surface of the second lower mold is formed to be larger than an area of the light guide plate.

[0018] A periphery of the upper surface of the second lower mold is positioned to extend beyond a periphery of the light guide plate.

[0019] The first lower mold and the second lower mold are installed to be movable upward and downward independently of each other.

[0020] The side surfaces of the first lower mold and the second lower mold are mounted in close contact with each other.

[0021] In the first injection step, the periphery of the light guide plate is injected by injecting molten resin into the space formed by the upper mold, the first lower mold, and the second lower mold.

[0022] The secondary injection step is to inject resin onto the bottom surface of the light guide plate so as to form a base together with the resin injected in the first injection step.

[0023] The method of manufacturing the decorative panel integrated with the light guide plate for a vehicle further includes: removing the panel by opening the first lower mold and the second lower mold from the upper mold; and then performing secondary injection.

[0024] According to the decorative panel integrated with the light guide plate for a vehicle and its manufacturing method of the present disclosure having the above structure, since the film-shaped light guide plate placed on the upper mold is injected into the base, the decorative panel for a vehicle is configured to integrate the light guide plate and the base according to the shape of the part to which the decorative panel is applied. Therefore, peeling of the adhesion part generated by adhering the light guide plate and the base in the prior manufacturing does not occur.

[0025] In addition, the process of adhering the light guide plate and the base using an adhesive becomes unnecessary.

[0026] Since the base surrounds the periphery of the light guide plate, a separate decoration process does not have to be performed. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 is a cross-sectional view showing a state in which a surface light-emitting panel according to the related art is installed.

[0028] Figure 2 is a cross-sectional view showing a bonding process of a surface light-emitting panel according to the related art.

[0029] Figure 3 is a front view showing a state in which a decorative panel for a vehicle manufactured by the method of manufacturing a decorative panel integrated with a light guide plate for a vehicle according to the present disclosure is installed on a door trim.

[0030] Figure 4 is along Figure 3 sectional view taken along line A-A of.

[0031] Figures 5A to 5D is a schematic diagram sequentially showing the steps of the method of manufacturing a decorative panel integrated with a light guide plate for a vehicle according to the present disclosure.

[0032] Figure 6 is a flowchart showing the method of manufacturing a decorative panel integrated with a light guide plate for a vehicle according to the present disclosure. DETAILED DESCRIPTION

[0033] In the following, a light guide plate integrated decorative panel for a vehicle and a manufacturing method thereof according to the present disclosure will be described in detail with reference to the accompanying drawings.

[0034] The decorative panel for a vehicle according to the present disclosure includes: a light guide plate 21 configured to diffuse light emitted from a light source 25; and a base 22 formed to surround the periphery and the bottom surface of the light guide plate 21.

[0035] The light guide plate 21 is made of a thin synthetic resin material. Since the light guide plate 21 is thin and has a film shape (for example, a thickness of 0.4 mm to 1.5 mm), the light guide plate 21 can be easily deformed according to the shape of the mold. The light guide plate 21 is made of a polycarbonate material having a good light transmittance, so that the light emitted from the light source is uniformly diffused.

[0036] Through the manufacturing method described later, the inserted light guide plate 21 is injected into the base 22, thereby becoming a decorative panel for a vehicle. The base 22 adheres to the periphery and the bottom surface of the light guide plate 21. The base 22 and the light guide plate 21 are not adhered using an adhesive, but are adhered by injecting the inserted light guide plate 21 into the base 22.

[0037] Specifically, in the present disclosure, the periphery of the light guide plate 21 is formed in a stepped shape and the base 22 holds the light guide plate 21, thereby preventing the light guide plate 21 from peeling off from the base 22.

[0038] The decorative panel for a vehicle can be installed inside the vehicle, for example, on a door trim 11. In the case of installing the decorative panel, the light emitted from the light source 25 can be diffused through the light guide plate 21, thereby illuminating the interior of the vehicle. By injecting the inserted light guide plate 21 into the base 22 later, it is possible to easily manufacture a curved surface, and even after a period of time, the light guide plate 21 and the base 22 do not peel off from each other.

[0039] When light is emitted from a light source 25 such as an LED lamp through the light guide plate 21, the light can be diffused over the entire area of the light guide plate 21 and then illuminate the interior of the vehicle, thereby enhancing the interior of the vehicle.

[0040] Since the light guide plate 21 and the base 22 are manufactured by the same upper mold 31, first lower mold 32, and second lower mold 33, the light guide plate 21 and the base 22 also have the same curved shape.

[0041] As follows will be referred to Figures 5A to 5D and Figure 6 to describe a method of manufacturing a light guide plate integrated decorative panel for a vehicle according to the present disclosure.

[0042] A method of manufacturing a light guide plate integrated decorative panel for a vehicle according to the present disclosure includes: placing a light guide plate 21 on the bottom surface of an upper mold 31 (S110); closing a lower mold such that a first lower mold 32 and a second lower mold 33, which are installed to be movable up and down below the upper mold 31, rise (S120); a first injection, forming a part of a base 22 around the light guide plate 21 by injecting molten resin between the upper mold 31 and the first lower mold 32 (S130); opening the second lower mold such that the second lower mold 33 descends, separating the second lower mold 33 in contact with the bottom surface of the light guide plate 21 from the bottom surface of the light guide plate 21 (S140); and a second injection, injecting molten resin between the light guide plate 21 and the second lower mold 33 (S150).

[0043] The placement of the light guide plate (S110) is to place the light guide plate 21 on the bottom surface of the upper mold 31 (see Figure 5A ).

[0044] When the base 22 is injected, the light guide plate 21 remains in its inserted state. Different from a metallic material such as steel, the light guide plate 21 made of a synthetic resin material requires a structure capable of maintaining the placement state to be applied. For this purpose, by forming a plurality of air holes 31a penetrating the upper mold 31 in the upper mold 31 and allowing the inside of the air holes 31a to become a negative pressure, the light guide plate 21 is kept in a state of being placed on the bottom surface of the upper mold 31. For example, the air holes 31a are connected to a negative pressure generating member 34, which is configured to generate a negative pressure to allow the inside of the air holes 31a to become a negative pressure, thereby maintaining the placement state. Here, the negative pressure generating member 34 may be a vacuum pump.

[0045] Preferably, with respect to the area where the light guide plate 21 is placed, the ventilation holes 31a are formed at regular intervals such that the light guide plate 21 is placed on the bottom surface of the upper mold 31 with a uniform adsorption force and is not pushed due to the injection pressure during the first injection (S130) and the second injection (S150).

[0046] Closing the lower mold (S120) is to move the first lower mold 32 and the second lower mold 33 together to the side of the upper mold 31, narrowing the interval between the first lower mold 32 and the second lower mold 33 and the upper mold 31 (see Figure 5A ).

[0047] When closing the lower mold (S120), the first lower mold 32 moves to be separated from the upper mold 31 by an interval corresponding to the thickness of the base 22, and the second lower mold 33 moves to contact the bottom surface of the light guide plate 21.

[0048] The first lower mold 32 and the second lower mold 33 are formed to be movable independently up and down below the upper mold 31. The side surfaces of the first lower mold 32 and the second lower mold 33 are in close contact with each other. The first lower mold 32 is located outside the second lower mold 33.

[0049] Therefore, the first lower mold 32 moves to be separated from the upper mold 31, and the second lower mold 33 is in close contact with the bottom surface of the light guide plate 21, so that the second lower mold 33 is used to support the lower part of the light guide plate 21. In addition, the base 22 is formed around the light guide plate 21 by injection.

[0050] In the present disclosure, although the molding surfaces of the upper mold 31, the first lower mold 32, and the second lower mold 33 are shown to be formed as flat surfaces, if the decorative panel needs to be formed as a curved surface, they are correspondingly formed as curved surfaces.

[0051] The first injection (S130) is to form a part of the base 22 around the light guide plate 21 by injecting molten resin between the upper mold 31 and the first lower mold 32.

[0052] The base 22 is formed to cover the periphery and the bottom surface of the light guide plate 21, and since the bottom surface of the light guide plate 21 is closed by the second lower mold 33, the first injection (S130) can be performed by injecting molten resin only between the upper mold 31 and the first lower mold 32.

[0053] At this time, as shown in the enlarged view of Figure 5B , since the periphery of the light guide plate 21 is vertically closed by the upper mold 31 and the second lower mold 33, the resin injected between the upper mold 31 and the first lower mold 32 is also injected between the upper mold 31 and the step portion (see the arrow).

[0054] Since the light guide plate 21 is constrained by the upper mold 31 and the second lower mold 33, the light guide plate 21 is not pushed during the first injection (S130).

[0055] Meanwhile, the first injection (S130) also includes the state of curing the resin.

[0056] Opening the second lower mold (S140) is to lower the second lower mold 33 so that the second lower mold 33 in contact with the bottom surface of the light guide plate 21 is separated from the bottom surface of the light guide plate 21 (see Figure 5C ).

[0057] Since it is the state where a part of the base 22 is formed by injection molding the periphery of the light guide plate 21 with resin, the second lower mold 33 descends so that a gap is formed between the light guide plate 21 and the second lower mold 33 in order to form the base 22 on the bottom surface of the light guide plate 21.

[0058] The secondary injection (S150) is to inject molten resin between the light guide plate 21 and the second lower mold 33 (see Figure 5D ).

[0059] In the secondary injection step (S150), when injecting molten resin between the light guide plate 21 and the second lower mold 33, the base portion 22 is formed on the bottom surface of the light guide plate 21, and at the same time, the base portion 22 formed around the light guide plate 21 during the first injection (S130) is integrally formed. Since the area of the upper surface of the second lower mold 33 is formed to be larger than the area of the light guide plate 21, the base portion 22 formed during the first injection (S130) is also exposed to the space formed by lowering the second lower mold 33. Therefore, when performing the secondary injection (S150), the base portion 22 is formed on the bottom surface of the light guide plate 21, and at the same time, the already formed base portion 22 is integrally formed.

[0060] At the same time, the secondary injection step (S150) also includes the state of curing the resin.

[0061] The panel removal step (S160) is to remove the decorative panel by opening the first lower mold 32 and the second lower mold 33 from the upper mold 31 when the molding of the decorative panel is completed by the upper mold 31, the first lower mold 32, and the second lower mold 33.

[0062] The decorative panel can be installed on one side of the vehicle interior (e.g., the door trim 11), thereby obtaining a surface light-emitting effect.

[0063] At the same time, the surface of the decorative panel (specifically, the surface of the base portion 22) can be attached with a film having a pattern or color, etc., or can be decorated with a decorative material for texture or touch.

[0064] In the present disclosure, the base portion 22 is formed by injecting the light guide plate 21 inserted between the upper mold 31, the first lower mold 32, and the second lower mold 33, thereby manufacturing a decorative panel in an adhered state without an adhesive.

[0065] Specifically, when the decorative panel has a curved shape, since the decorative panel is manufactured by the same upper mold 31, first lower mold 32, and second lower mold 33, the light guide plate 21 and the base portion 22 have the same curved shape, so that even after a period of time, the adhered portion between the light guide plate 21 and the base portion 22 will not separate.

Claims

1. A method of manufacturing a light guide plate integrated decorative panel for a vehicle, the method manufacturing the decorative panel, the decorative panel comprising: a light guide plate configured to uniformly diffuse light emitted from a light source; and a base attached to one side surface of the light guide plate and to which the decorative panel is mounted inside the vehicle, the method of manufacturing the light guide plate integrated decorative panel for a vehicle comprising: placing the light guide plate on the bottom surface of the upper mold; closing the lower mold such that a first lower mold and a second lower mold mounted to be movable up and down below the upper mold rise; first injection, forming a part of the base around the light guide plate by injecting molten resin between the upper mold and the first lower mold; opening the second lower mold to lower the second lower mold such that the second lower mold in contact with the bottom surface of the light guide plate is spaced apart from the bottom surface of the light guide plate; and second injection, injecting the molten resin between the light guide plate and the second lower mold, wherein, when closing the lower mold, the first lower mold moves to be spaced apart from the upper mold by an interval corresponding to the thickness of the base, and the second lower mold moves to contact the bottom surface of the light guide plate.

2. The method of manufacturing a light guide plate integrated decorative panel for a vehicle according to claim 1, wherein, placing the light guide plate allows the interior of the air hole formed through the upper mold to become negative pressure and positions the light guide plate on the bottom surface of the upper mold such that the light guide plate is placed on the bottom surface of the upper mold.

3. The method of manufacturing a light guide plate integrated decorative panel for a vehicle according to claim 1, wherein, the area of the upper surface of the second lower mold is formed to be larger than the area of the light guide plate.

4. The method of manufacturing a light guide plate integrated decorative panel for a vehicle according to claim 3, wherein, the periphery of the upper surface of the second lower mold is further positioned outside the periphery of the light guide plate.

5. The method of manufacturing a light guide plate integrated decorative panel for a vehicle according to claim 1, wherein, the first lower mold and the second lower mold are mounted to be movable up and down independently of each other.

6. The method of manufacturing a light guide plate integrated decorative panel for a vehicle according to claim 5, wherein, the side surfaces of the first lower mold and the second lower mold are mounted to be in close contact with each other.

7. The method of manufacturing a light guide plate integrated decorative panel for a vehicle according to claim 1, wherein, in the first injection, the periphery of the light guide plate is injected by injecting the molten resin into the space formed by the upper mold, the first lower mold, and the second lower mold.

8. The method of manufacturing a light guide plate integrated decorative panel for a vehicle according to claim 1, wherein, the second injection is injecting resin onto the bottom surface of the light guide plate so as to form the base together with the resin injected in the first injection.

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