Layer structure with 3D structure and 2D projection of said structure

Abstract

The invention relates to a layer structure, which comprises: a film layer (100) provided with optical information, and a three-dimensional structured layer (200) having a smooth side (210) and a structured side (220) opposite to the smooth side (210), wherein the structured side (220) has at least one region (230) which is not coplanar with the smooth side (210) and faces a predetermined reference position (400), and wherein the structured side (220) has at least one region (235) which is not coplanar with the smooth side (210) and faces away from the predetermined reference position (400). The three-dimensional structured layer (200) is formed from a thermoplastic polymer, which has a visual clarity Ty (D65 / 10°) of ≥10% according to ASTM D1003 at a layer thickness of 4 mm. The film layer (100) provided with optical information is bonded to the structured side (220) of the three-dimensional structured layer (200). The film layer (100) equipped with optical information is printed with at least one portion of a two-dimensional projection (500) of a three-dimensional structured layer (200), and the projection (520) of the at least one area (230) facing the reference position (400) is presented on the film layer (100) equipped with optical information in a manner different from the presentation of the projection (530) of the at least one area (235) facing away from the reference position (400).

Description

[0001] The invention relates to a layer structure, which comprises: a film layer provided with optical information, and a three-dimensional structured layer having a smooth side and a structured side opposite to the smooth side. The structured side has at least one area which is not coplanar with the smooth side and faces a predetermined reference position, and the structured side has at least one area which is not coplanar with the smooth side and faces away from the predetermined reference position. The three-dimensional structured layer is formed from a thermoplastic polymer which has a visual clarity Ty (D65 / 10°) of ≥ 10% according to ASTM D1003 at a layer thickness of 4 mm, and the film layer provided with optical information is bonded to the structured side of the three-dimensional structured layer.

[0002] WO 2009 / 083198 A1 describes a method for three-dimensionally reproducing relief prototypes and / or image prototypes, wherein a graphic representation, in particular a printed smooth thermoplastic film, provided with the relief prototype and / or image prototype, is used as a relief substrate and a positive relief mold, wherein during a thermoplastic deformation step, the film and the positive relief mold are superimposed on each other with an exact fit and thermoplastically deformed under the influence of heat. In WO 2009 / 083198 A1, it is claimed that a solution for providing a simplified method for reproducing relief and / or image prototypes has been achieved. According to WO 2009 / 083198 A1, this is achieved by carrying out the following steps: a) providing a thermoplastic film in advance, b) arranging a relief mold substrate in precise contact on the image side of the film or at a small distance by means of position marks of their position relative to one another, through which the film is visible, c) applying a relief structure to the face of the relief mold substrate facing away from the image side of the film corresponding to the graphic presentation by applying a relief mold material which shapes and forms a positive relief mold, d) introducing the positive relief mold into a heat treatment device, e) placing the face of the film facing away from the image in precise contact on the structured top face of the positive relief mold corresponding to the position marks from step b), and f) carrying out thermoplastic deformation and / or embossing of the film.

[0003] Three-dimensional relief patterns can create aesthetically pleasing decorative elements. However, the disadvantage to date has been that the more visual "depth" the designer wants to achieve, the more material must be processed.

[0004] The object of the invention is to provide a layer structure which, at a reduced overall thickness, still achieves a three-dimensional depth impression of the three-dimensional structures contained in the layer structure. With such a layer structure, aesthetically appealing decorative elements, for example for vehicle interiors, can be produced without having to process excessive amounts of material.

[0005] This object is achieved according to the invention by a layer construction as claimed in claim 1. The subject matter of claim 14 is a production method. Advantageous further developments are given in the dependent claims. They can be combined in any desired manner, unless the context clearly indicates otherwise.

[0006] By means of the layer construction according to the invention, attractive three-dimensional effects can be achieved with reduced building thickness and thus material savings by optical interaction of 3D structures and 2D projections of these structures.

[0007] The present invention is explained in more detail with reference to the following drawings, but is not limited thereto, in which:

[0008] Figure 1 Shows the layer configuration and projection according to the invention;

[0009] Figures 2 to 5 A further layer structure according to the invention is shown.

[0010] Figure 1 The layer structure according to the invention is schematically shown, which has a film layer 100 provided with optical information and a three-dimensional structured layer 200 having a smooth side 210 and a structured side 220 opposite the smooth side 210. The "optical information" can be presented here by different printings (in this case the film 100 is a printed film), coloring or surface roughness in selected areas of the film 100. It is also possible for the film 100 to be conceived as a light conductor and for the optical information to be presented by selective coupling-out of light that has been laterally coupled into the film 100.

[0011] There is no restriction on the location of the information in or on the film 100. The information may thus be present on the side of the film 100 facing the structured layer 200, may be present on the side of the film 100 facing away from the structured layer 200 or may be present within the film 100.

[0012] The layer structure can be designed to be flat or non-flat (curved). Accordingly, the smooth surface 210 can exist in the form of a flat surface or a curved surface. The smooth surface 210 preferably has no protrusions or recesses other than technically unavoidable undulations.

[0013] The structured surface 220 has at least one area 230 that is not coplanar with the smooth surface 210 and faces a predetermined reference position 400. Such an area 230 is formed by a protrusion or peak 240 and / or a recess or valley 250 on the structured surface 220. The reference position 400 can be a reference point. It can be understood as an imaginary position of an observer's eye or a light source (used to generate or simulate a projected shadow on the structured surface 220). The structured surface 220 also has at least one area 235 that is not coplanar with the smooth surface 210 and faces away from the predetermined reference position 400.

[0014] The three-dimensional structured layer 200 is formed from a thermoplastic polymer which, at a layer thickness of 4 mm, has a visual clarity Ty (D65 / 10°) of ≥ 10% according to ASTM D1003. The 3D structured layer 200 can therefore be regarded as transparent or at least partially transparent.

[0015] Examples of suitable thermoplastic polymers are members selected from polycarbonates, polyester carbonates, polystyrenes, polyamides, styrene copolymers, aromatic polyesters, PET-cyclohexanedimethanol copolymers (PETG), polyethylene naphthalate (PEN), polybutylene terephthalate (PBT), poly- or copolymerized polyacrylates and poly- or copolymerized methacrylates and copolymers with styrene.

[0016] The term polycarbonate also includes copolycarbonates. In the case of styrene copolymers, preference is given to acrylonitrile-styrene-acrylate copolymers (ASA), in the case of aromatic polyesters preference is given, for example, to polyethylene terephthalate (PET), in the case of poly- or copolymerized methacrylates preference is given to poly- or copolymerized methyl methacrylate, in particular polymethyl methacrylate (PMMA), and in the case of copolymers with styrene preference is given to transparent polystyrene-acrylonitrile (PSAN).

[0017] Of course, the thermoplastic polymer may contain additives, such as colorants, stabilizers, impact modifiers, etc. The visual clarity Ty is preferably ≥ 20% to ≤ 99%, more preferably ≥ 50% to ≤ 92%.

[0018] The film layer 100 provided with optical information is joined to the structured surface 220 of the three-dimensional structured layer 200. This can be achieved, for example, in a film-back injection molding process. Preferably, the film 100 follows the contour of the structured surface 220. This is also shown in Figure 1 middle.

[0019] In the layer construction according to the invention, it is provided that the optical information of the film layer 100 provided with the optical information represents at least a part of the two-dimensional projection 500 of the three-dimensional structured layer 200. Preferably, the film layer 100 is provided with the complete projection of the 3D structured layer 200. For the sake of clarity, the projection 500 is Figure 1 In projection 500, which represents the entire projection, projections 510, 520 and 530 can be distinguished, which are bounded from one another by elevations 240 and depressions 250 of structured surface 220. Projection 500 thus contains at least projections 520 and 530.

[0020] The projection 520 of the at least one area 230 facing the reference position 400 is presented on the film layer 100 provided with optical information in a different manner than the projection 530 of the at least one area 235 facing away from the reference position 400. By facing or facing away from the reference position 400, it is possible, for example, to define a lighting effect or a shadow effect of these areas. This can be compared to the presentation of a mountain range (a three-dimensional structure) in a map (a two-dimensional structure). A reference position for the light source is selected, and on this basis, the slopes facing away from the light source are presented in a darker or shadowed form. This results in a three-dimensional impression of the mountain range on the map.

[0021] The projection 500 may be obtained by converting the three-dimensional CAD model of the structured layer 200 into a two-dimensional image using a ray tracing method.

[0022] In projection 500, horizontal sections of structured surface 220 may not be colored or otherwise represented by optical information. This is also represented by projection 510. Figure 1 By discarding their coloring, the optical impression of the other projections 520 and 530 is enhanced.

[0023] Also shown in Figure 1 In one embodiment, projection 500 is an orthogonal projection without offset. Film 100 together with the projection is now superimposed with structured surface 220.

[0024] Also shown in Figure 1 In another embodiment of the invention, the reference position 400 faces the smooth side 210 of the three-dimensional structured layer 200. The layer structure according to the invention can be used as a decorative surface or decorative element. Preferably, the smooth side 210 is the side facing the observer, so that the reference point 400 is a possible position of the observer.

[0025] Also shown in Figure 1 In another embodiment of the invention, the reference position 400 is arranged outside the vertical boundaries of the layer construction.

[0026] Figure 2 show Figure 1 , without projection 500 and, for a better overview, without the film layer 100 provided with optical information, but with additional geometric descriptors h, n1, n2 and α. In another embodiment, the maximum vertical distance between a peak 240 and an adjacent valley 250 in the structured surface 220 of the three-dimensional structured layer 200 is ≤ 2 mm. The distance h is preferably ≥ 0.1 mm to ≤ 1.5 mm, more preferably ≥ 0.2 mm to ≤ 0.9 mm. In any case, the height h can be selected so that the peak 240 associated therewith protrudes beyond the horizontal plane of the structured surface 220. This is exemplarily depicted in Figure 3 In. Figure 3In the drawings, for the sake of a better overview, the film layer 100 provided with optical information is likewise not represented.

[0027] These limiting values ​​for the distance h have the advantage that the three-dimensional structure is so flat that the film does not have to be preformed during production of the layer construction but can be inserted into the injection mold as a two-dimensional film (for film post-injection molding).

[0028] Another advantage of these limit values ​​of the distance h is that the optical quality of the smooth surface 210 can be improved. If the height difference in the structured surface 220 is smaller, that is, the smaller h is, the mass fluctuation of the thermoplastic polymer perpendicular to the smooth surface 210 is also smaller when viewed as a whole. This now leads to a more uniform cooling behavior of the thermoplastic. Optical defects caused by uneven cooling of the thermoplastic are thus avoided. By combining with the film 100, an attractive three-dimensional visual impression is still obtained in this layer structure.

[0029] Also shown in Figure 2 In another embodiment of the invention, the surface normal n1 of the region 230 facing the reference position 400 and the surface normal n2 of the adjacent region 235 facing away from the reference position 400 intersect at an angle α of ≥ 5° to ≤ 175°. This allows the slope of the regions 230, 235 to be quantified. The angle α is preferably ≥ 20° to ≤ 70°, more preferably ≥ 30° to ≤ 60°.

[0030] In another embodiment, the film layer 100 is provided with optical information by means of laser structuring, inkjet printing, laser printing, digital printing or screen printing. Printing methods, such as screen printing, are preferred, so that the film layer 100 is a printed film layer, the printed film layer 100 is printed with at least one part of the two-dimensional projection 500 of the three-dimensional structured layer 200, and the projection 520 of the at least one area 230 facing the reference position 400 is presented on the printed film layer 100 in a different manner than the projection 530 of the at least one area 235 facing away from the reference position 400.

[0031] In the reference Figure 1In another embodiment, the projection 520 of the at least one area 230 facing the reference position 400 has a lower tone value on the film layer 100 equipped with optical information than the projection 530 of the at least one area 235 facing away from the reference position 400. The term tone value refers to the different levels between light and dark in a color image or black and white image in the form of photography or printing in a digital data set, on a transparent carrier (film) or in a top view. The term describes the color value or grayscale value shown in a predetermined color level spectrum or grayscale spectrum from 0 to 100% in the case of an image element (point). 100% here refers to the maximum darkness or color coverage (maximum tone) of the imaging medium. Correspondingly, 0% refers to the complete transparency of the film or blank paper during matrix printing (Rasterdrucken). The tone value is determined by the measurement of optical density / reflectivity and is calculated from these measured values ​​according to the Murray-Davies formula.

[0032] In the superimposed CMYK color model used in the printing method, the gray value can be expressed as a percentage of the component K ("hue", black). Preferably, on the film layer 100 provided with optical information, the projection 520 of the at least one area 230 facing the reference position 400 has a lower gray value in the CMYK color model than the projection 530 of the at least one area 235 facing away from the reference position 400. In the simplified analogy above, the "hillside" facing away from the light source appears darker than the "hillside" facing the light source.

[0033] In the same reference Figure 1 In another embodiment, the hue value of the projection 520 of the at least one region 230 facing the reference position 400 is selected as a function of the slope of the region 230 with the horizontal plane. In the simplified analogy above, the "hills" facing the light source appear differently depending on their slope.

[0034] In the same reference Figure 1 In another embodiment, the tonal value of the projection 530 of the at least one region 235 facing away from the reference position 400 is selected as a function of the slope of the region 235. In the simplified analogy above, the "hills" facing away from the light source appear differently, in particular darker, depending on their slope.

[0035] The functions in the two last-mentioned embodiments can, for example, be independently of each other linear functions or logarithmic functions. Logarithmic functions are advantageous for reflecting the logarithmic nature of human sensory perception.

[0036] exist Figure 4 and 5In another embodiment depicted in FIG, a first additional layer 300 is also present on the side of the film layer 100 provided with optical information facing away from the structured side 220 of the three-dimensional structured layer 200, which is bonded to the layer. Additionally or alternatively, a second additional layer 310 is also present on the smooth side 210 of the three-dimensional structured layer 200, which is bonded to the layer. The first additional layer 300 and the second additional layer 310 can be realized independently of each other by means of a film, a lacquer, by vapor deposition or by plasma coating. Such additional layers 300, 310 can protect the layer structure from stains or scratches.

[0037] In another embodiment, the thermoplastic polymer used to form the three-dimensional structured layer 200 is a polycarbonate. The term also covers copolycarbonates and polycarbonate blends. The melt volume flow rate MVR of the polycarbonate measured according to ISO 1133-1:2012-03 (300°C, 1.2 kg) can be 8 to 20 cm³ / (10 min). Preferred are homopolycarbonates based on bisphenol A, homopolycarbonates based on 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane, homopolycarbonates containing isosorbide, 2,3-dihydro-3,3-bis(4-hydroxyphenyl)-2-methyl-1 H -isoindol-1-one, 2,3-dihydro-3,3-bis(4-hydroxyphenyl)-2-phenyl-1 H -isoindol-1-one, 1,3-dihydro-3,3-bis(4-hydroxyphenyl)-1-methyl-2 H -indol-2-one, 1,3-dihydro-3,3-bis(4-hydroxyphenyl)-1-phenyl-2 H -indol-2-one, 1,2-dihydro-2,2-bis(4-hydroxyphenyl)-1-methyl-3 H -indol-3-one and / or 1,2-dihydro-2,2-bis(4-hydroxyphenyl)-1-phenyl-3 H -copolycarbonates of indole-3-one, copolycarbonates based on the monomers bisphenol A and 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane, or mixtures of at least two of the above polymers. The polycarbonates may of course contain additives such as dyes, stabilizers, impact modifiers and the like.

[0038] The film layer 100 preferably comprises one or more thermoplastic polymers. Examples have been mentioned above. In another embodiment, the film layer 100 provided with optical information comprises a polycarbonate. This term also covers copolycarbonates and polycarbonate blends. The melt volume flow rate MVR of the polycarbonate measured according to ISO 1133-1:2012-03 (300°C, 1.2 kg) can be 8 to 20 cm³ / (10 min). Preferred are homopolycarbonates based on bisphenol A, homopolycarbonates based on 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane, homopolycarbonates containing isosorbide, 2,3-dihydro-3,3-bis(4-hydroxyphenyl)-2-methyl-1 H -isoindol-1-one, 2,3-dihydro-3,3-bis(4-hydroxyphenyl)-2-phenyl-1 H -isoindol-1-one, 1,3-dihydro-3,3-bis(4-hydroxyphenyl)-1-methyl-2 H -indol-2-one, 1,3-dihydro-3,3-bis(4-hydroxyphenyl)-1-phenyl-2 H -indol-2-one, 1,2-dihydro-2,2-bis(4-hydroxyphenyl)-1-methyl-3 H -indol-3-one and / or 1,2-dihydro-2,2-bis(4-hydroxyphenyl)-1-phenyl-3 H -copolycarbonates of indole-3-one, copolycarbonates based on the monomers bisphenol A and 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane, or mixtures of at least two of the above polymers. The polycarbonates may of course contain additives such as dyes, stabilizers, impact modifiers and the like.

[0039] In another embodiment, the first additional layer 300 and / or the second additional layer 310 consists of a two-component paint (2K paint), a coextruded film or a scratch-resistant coated film. Preferably, the scratch-resistant coated film is a polycarbonate film provided with a coating containing silicon oxide nanoparticles.

[0040] In another embodiment, it is applicable that the thickness of the film layer 100 provided with optical information is ≥ 100 µm to ≤ 1000 µm (preferably ≥ 175 µm to ≤ 500 µm, more preferably ≥ 250 µm to ≤ 375 µm), and / or the maximum thickness of the three-dimensional structured layer 200 is ≥ 1.5 mm to ≤ 6 mm (preferably ≥ 2 mm to ≤ 5 mm, more preferably ≥ 3 mm to ≤ 4 mm).

[0041] The layer construction according to the invention can be used as a decorative part or decorative surface. Preferred areas of application are exterior or interior parts of vehicles.

[0042] The method for producing the layer construction according to the invention comprises the following steps:

[0043] - selecting a three-dimensional structure, wherein the structure has at least one region 230 which has an inclination with respect to the horizontal and faces a predetermined reference position 400

[0044] and

[0045] wherein the structure has at least one region 235 which is inclined with respect to the horizontal plane and faces away from the predetermined reference position 400,

[0046] - generating on the film 100 optical information representing at least a portion of the two-dimensional projection 500 of the selected three-dimensional structure,

[0047] wherein the projection 520 of the at least one region 230 facing the reference position 400 is presented on the film 100 in a manner different from the presentation of the projection 530 of the at least one region 235 facing away from the reference position 400,

[0048] - producing a three-dimensional structured layer 200 corresponding to the selected three-dimensional structure from a thermoplastic polymer, wherein the polymer has a visual clarity Ty (D65 / 10°) according to ASTM D1003 of ≥ 10% at a layer thickness of 4 mm,

[0049] So that the three-dimensional structured layer 200 has a smooth surface 210 and a structured surface 220 opposite to the smooth surface 210;

[0050] - Bonding the film 100 to the structured face 220 of the three-dimensional structured layer 200 .

[0051] The embodiments mentioned in connection with the subject matter of the invention can of course also be transferred to the method. The optical information on the film 100 can thus preferably be produced by printing, and the film 100 is preferably joined to the layer 200 in such a way that the projection of the 3D structure coincides with the structured surface 220 .

Claims

1. A layer structure for a decorative element, comprising: A film layer (100) provided with optical information and A three-dimensional structured layer (200) having a smooth surface (210) and a structured surface (220) opposite to the smooth surface (210), The structured surface (220) has at least one first region (230) that is not coplanar with the smooth surface (210). and The structured surface (220) has at least one second region (235) that is not coplanar with the smooth surface (210), wherein the first region (230) and the second region (235) form an angle not equal to 180°, wherein the three-dimensional structured layer (200) is formed from a thermoplastic polymer which, at a layer thickness of 4 mm, has a visual clarity Ty (D65 / 10°) according to ASTM D1003 of ≥10%, and The film layer (100) provided with optical information is bonded to the structured surface (220) of the three-dimensional structured layer (200), Features The optical information of the film layer (100) provided with optical information represents at least a portion of a two-dimensional projection (500) of the three-dimensional structured layer (200), wherein the two-dimensional projection (500) is an orthogonal projection without offset, wherein the maximum vertical distance h between a peak (240) and an adjacent valley (250) in the structured surface (220) of the three-dimensional structured layer (200) is ≤ 2 mm, and The projection (520) of the at least one first area (230) is presented on the film layer (100) provided with optical information in a manner different from the projection (530) of the at least one second area (235).

2. A layer construction as claimed in claim 1, wherein the thermoplastic polymer is selected from the following members: polycarbonate, polyester carbonate, polystyrene, polyamide, styrene copolymers, aromatic polyesters, poly(ethylene terephthalate-1,4-cyclohexanedimethanol ester) (PETG), poly- or co-polyacrylates, co-polymethyl methacrylate (PMMA), polystyrene-acrylonitrile (PSAN).

3. A layer construction as claimed in claim 1, wherein the thermoplastic polymer is selected from the following members: copolycarbonates, poly- or comethacrylates, polyethylene naphthalate (PEN), polybutylene terephthalate (PBT).

4. The layer structure as claimed in claim 1, wherein the surface normal n1 of the first region (230) and the surface normal n2 of the adjacent second region (235) intersect at an angle α of ≥5° to ≤175°.

5. The layer structure as claimed in claim 1, wherein the film layer (100) is provided with optical information by means of laser structuring, inkjet printing, laser printing or screen printing.

6. A layer structure as claimed in claim 1, wherein the projection (520) of the at least one first area (230) has a lower tonal value than the projection (530) of the at least one second area (235) on the film layer (100) provided with optical information.

7. A layer construction as claimed in claim 6, wherein the tonal value of the projection (520) of the at least one first region (230) is selected as a function of the inclination of the first region (230) to the horizontal plane.

8. A layer construction as claimed in claim 6, wherein the tonal value of the projection (530) of the at least one second region (235) is selected as a function of the inclination of the second region (235) to the horizontal plane.

9. A layer structure as described in claim 1, wherein there is a first additional layer (300) bonded to the three-dimensional structured layer (200) on the surface of the structured surface (220) of the film layer (100) equipped with optical information facing away from the layer, and / or there is a second additional layer (310) bonded to the layer on the smooth surface (210) of the three-dimensional structured layer (200).

10. A layer construction as claimed in claim 1, wherein the thermoplastic polymer used to form the three-dimensional structured layer (200) is polycarbonate.

11. A layer construction as claimed in claim 1, wherein the film layer (100) provided with the optical information comprises polycarbonate.

12. The layer construction as claimed in claim 9, wherein the first additional layer (300) and / or the second additional layer (310) is formed from a two-component lacquer, from a coextruded film or a film having a scratch-resistant coating.

13. The layer structure as claimed in claim 1, wherein: The thickness of the film layer (100) provided with optical information is ≥100 μm to ≤1000 μm and / or The maximum thickness of the three-dimensional structured layer (200) is ≥1.5 mm to ≤6.0 mm.

14. A method for producing a layer structure as claimed in any one of claims 1 to 13, comprising the following steps: - selecting a three-dimensional structure, wherein the structure has at least one first region having an inclination with respect to a horizontal plane (230) and wherein the structure has at least one second region (235) having an inclination relative to a horizontal plane, wherein the first region (230) and the second region (235) form an angle not equal to 180°, - generating optical information on the film (100) which represents at least a portion of the two-dimensional projection (500) of the selected three-dimensional structure, wherein the projection (520) of the at least one first region (230) is presented on the film (100) in a manner different from the projection (530) of the at least one second region (235), - producing a three-dimensional structured layer (200) corresponding to the selected three-dimensional structure from a thermoplastic polymer, wherein the polymer has a visual clarity Ty (D65 / 10°) according to ASTM D1003 of ≥10% at a layer thickness of 4 mm, So that the three-dimensional structured layer (200) has a smooth surface (210) and a structured surface (220) opposite to the smooth surface (210); - Joining the film (100) to the structured face (220) of the three-dimensional structured layer (200).

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