Layered decorative structure

Abstract

A layered decorative structure includes: an outer layer including a stitch pattern and at least one region configured to allow light transmission; an elastically compressible spacer layer configured to allow light transmission; and an at least partially opaque masking layer disposed between the outer layer and the spacer layer, the masking layer configured to have at least one opening positionally corresponding to at least one area configured to allow light transmission.

Description

Technical Field

[0001] The present invention relates to improvements in or relating to light emitting fabrics. In particular, but not exclusively, the present invention relates to light emitting fabrics for use in the trim and interior of vehicles. Background Art

[0002] Vehicles are known to include decorative arrangements that include layered materials. Typically, the material includes a decorative outer layer that covers an inner layer made of a spacer material. The outer layer is aesthetically pleasing (tactile and / or visual) and is typically made of leather, fabric or cloth (whether natural or synthetic). Typically, the spacer material is resiliently compressible so as to provide a soft touch and is often provided in the form of a foam or fabric.

[0003] In luxury vehicles, trim arrangements often include decorative patterns on their exterior surfaces, created using methods that may include stitching and / or perforations. While decorative, any such stitching often also serves to attach the exterior and spacer materials to each other.

[0004] It is also known, particularly in luxury cars, to use layered materials such as quilted leather to provide a 3D surface. This is achieved by sewing the outer layer (in this case leather) and the spacer material together in a quilted pattern that compresses the spacer material near the stitching to provide a 3D quilted effect because the spacer fabric is less compressed in areas further away from the stitching.

[0005] Typically, once the layered material has been formed, an adhesive is used to attach the spacer material directly to a rigid support substrate, which enables the trim and / or soft-surface components to be fastened to the vehicle as required. This also serves to accentuate the 3D texture of the material, as the rigidity of the support surface ensures that the spacer fabric pushes against the outer layer.

[0006] It is also known to provide a vehicle trim component that is luminous. In such a case, the spacer material is (at least partially) translucent and / or transparent, thereby allowing the spacer material to transmit light. In such a trim component, when a light source is provided, the spacer material is able to transmit light through the outer layer (and, in the case of perforations, through any perforations therein).

[0007] One problem associated with such illuminated decorative components is that the decorative stitching and / or any stitching attaching the outer layer to the spacer material also allows light to be transmitted through the outer layer. In some, but not all, cases, this can provide an undesirable aesthetic appearance.

[0008] It is an object of the present invention to provide a layered material which at least partially overcomes and / or ameliorates these problems. Summary of the invention

[0009] According to a first aspect of the present invention, a layered decorative structure is provided, comprising: an outer layer comprising a stitching pattern and at least one area configured to allow light transmission; an elastically compressible spacer layer configured to allow light transmission; and an at least partially opaque masking layer disposed between the outer layer and the spacer layer, the masking layer being configured with at least one opening, the at least one opening corresponding in position to at least one area configured to allow light transmission.

[0010] Preferably, the at least partially opaque shielding layer will effectively prevent light from passing except where openings are formed through the at least partially opaque shielding layer. Specifically, the at least partially opaque shielding layer may include at least one shielding portion corresponding to the stitching pattern of the outer layer.

[0011] Providing a layered decorative structure having an at least partially opaque obscuring layer as described above allows light to pass through the spacer layer and through at least one area of ​​the outer layer configured to allow light transmission so as to be visible, but it prevents light passing through the spacer layer from passing through the obscuring portion, particularly the stitching in the outer layer. This can be used to ensure that the layered decorative structure includes a stitching pattern on the outer layer, but only allows light to pass where the at least partially opaque obscuring layer has at least one opening, which in turn is aligned with the at least one area configured to allow light transmission.

[0012] According to a second aspect of the present invention, there is provided a method for manufacturing a layered decorative structure, the method comprising the following steps:

[0013] providing a stitching pattern and at least one region in the outer layer configured to allow light transmission;

[0014] positioning an at least partially opaque obscuring layer including at least one opening relative to the outer layer such that the at least one opening in the obscuring layer corresponds in position to at least one area in the outer layer configured to allow transmission of light, and

[0015] A resiliently compressible spacer layer is positioned to sandwich the at least partially opaque obscuring layer to the outer layer, the resiliently compressible spacer layer being configured to allow light to be transmitted to the at least partially opaque obscuring layer.

[0016] As with the device, the at least partially opaque shielding layer will effectively prevent light from passing except where openings are formed through the at least partially opaque shielding layer. Specifically, the at least partially opaque shielding layer may include at least one shielding portion corresponding to the stitching pattern of the outer layer.

[0017] The method preferably comprises the step of laminating the outer layer, the obscuring layer and the spacing layer together in a laminating step.

[0018] The method preferably comprises the further step of deforming the spacer layer to a reduced thickness corresponding to the stitching pattern in the embossing step. The deformed, reduced thickness spacer layer may be formed by compression of the spacer layer corresponding to the stitching pattern. Preferably, any deformation of the spacer layer corresponding to the stitching pattern will be permanent.

[0019] This can be achieved in a variety of ways, such as using a welding machine. A welding machine can be used to compress the spacer layer at a suitable temperature and / or pressure. A hot press can be used to compress the spacer layer at a suitable temperature and / or pressure. A hand roller can be used to compress the spacer layer at a certain temperature and / or pressure.

[0020] The spacer layer may be formed or deformed before the shielding layer and / or the outer layer are attached. For example, the spacer layer may be molded before being attached to the shielding layer and / or the outer layer and attached in a pre-molded or already molded form.

[0021] The spacer layer can be attached to the shielding layer, which is simultaneously attached to the outer layer. Alternatively, the shielding layer can be attached to the outer layer, and then the spacer layer can be attached to the shielding layer. Alternatively, the spacer layer can be attached to the shielding layer and then attached to the outer layer.

[0022] Deforming of the spacing layer may be achieved simultaneously with or as a result of attaching the respective layers together.

[0023] A further step is to press the various layers together using a heat press having at least one raised portion corresponding to the stitching pattern in the outer layer to hold the layered decorative structure together and to plastically deform the spacer layer corresponding to the stitching pattern.

[0024] The lamination step and the embossing step can be performed simultaneously using the same equipment. The lamination step can be performed without the embossing step. The lamination step can be performed before the embossing step or after the embossing step.

[0025] The at least one area configured to allow light transmission may include at least one perforation through the opaque outer layer. However, the outer layer may be or include a fabric that may allow light transmission.

[0026] More than one perforation may be provided in at least one perforated area. Each perforation may be aligned with a corresponding opening in the shielding layer. This may provide a brighter, sharper lighting effect, given that the area around each perforation is shielded, but it may be difficult to obtain sufficiently precise alignment. This may be achieved by forming a stitching pattern in the outer layer, then attaching or applying the shielding layer to the outer layer and perforating through both layers simultaneously.

[0027] Alternatively, the opening may be aligned with each of the at least one perforated area. This may make alignment simpler given the larger area involved and less problematic with light leakage from one perforation through one or more adjacent perforations.

[0028] According to a third aspect of the present invention, a luminous vehicle ornament is provided, which includes: an outer layer, the outer layer including a stitching pattern and configured to allow light transmission to the at least one area; an elastically compressible spacer layer; an at least partially opaque shielding layer, the at least partially opaque shielding layer is arranged between the outer layer and the spacer layer, the shielding layer is configured to have at least one opening, and the opening corresponds in position to at least one area configured to allow light transmission; and a light source, the outer layer and the spacer layer each have an outer surface and an inner surface, the outer surface of the spacer layer faces the inner surface of the outer layer, and wherein the spacer layer is made of a material that allows light to pass through the spacer layer, and the light source is operable in use to guide light through the spacer layer to the outer cover so that it is visible through at least one area configured to allow light transmission.

[0029] The outer layer may be a flexible material which may be artificial or natural. The outer layer may be a leather, fabric or cloth material. The outer layer may be made of an opaque material, in which case the outer layer may be perforated to allow light transmission. When the outer layer is leather, it may be scraped and / or it may be bi-cast natural leather.

[0030] The outer layer may have any thickness from 0.1 mm to 6.0 mm, but will preferably be from 0.5 mm to 3 mm thick, and more preferably from 0.6 mm to 1.2 mm thick.

[0031] The outer layer will preferably be cut into the shape required for the decorative structure. The outer layer is preferably perforated. Cutting into shape and perforation can be achieved in the same step or in different steps. In one form, a die cutting press can be used, however, other suitable methods include laser or numerical control (CNC) cutting. Once cut, this allows control and reproducibility of the shape of the outer layer and / or the position of the perforations in the outer layer.

[0032] The outer layer may be provided with one or more extensions or tabs extending outwardly from the outer edge of the outer layer. Each of the one or more extensions or tabs may be provided with an opening or hole therethrough. The one or more extensions or tabs with openings or holes may be used to position the outer layer on a laminating press, to position the outer layer during stitching and / or in an embossing press. The one or more extensions or tabs may also help position and maintain the decorative structure during decorating the substrate. Preferably, the outer layer is positioned with the "A" surface facing downward and the "B" surface facing upward. In the press, the shielding layer may be directly located on the "B" surface of the outer layer.

[0033] At least one perforation may be formed through the outer layer. Preferably, a plurality of perforations are provided. Any number of perforations may be provided. The perforations may be provided in any pattern or shape. The perforations may be provided in one or more clusters, regions or arrays. Where provided in one or more clusters, regions or arrays, a border portion without perforations may be provided, preferably around each cluster, region or array.

[0034] The stitching provided in the outer layer may be embroidered into the outer layer. In one form, a CNC embroidery machine may be used. Again, this provides control and reproducibility of the form and position of the stitching on the outer layer. Preferably, the stitching only enters the outer layer. This is in contrast to prior art methods where stitching is applied through the outer layer and the base (spacer layer) to create a quilted effect.

[0035] The stitching may have any configuration. The stitching may be provided by surrounding a border portion of one or more clusters, regions or arrays.

[0036] An at least partially opaque shielding layer is preferably arranged between the outer layer and the spacing layer, the shielding layer being configured with at least one opening corresponding in position to the at least one perforation.

[0037] The obscuring layer may have any thickness from 0.02mm to 5.0mm. In a more preferred form, the obscuring layer may be in the range of 0.02mm-2mm, but will preferably be approximately 0.5mm thick.

[0038] The obscuring layer may preferably be cut into a shape corresponding to the stitching into the outer layer and the configuration of at least one area configured to allow light transmission.The obscuring layer may be cut into shape using a die cutting press.

[0039] The shielding layer will preferably have at least one opening that corresponds in position to at least one area configured to allow light transmission. As described above, an opening may be provided for each perforation. In this case, precision will be required between the position of the opening in the shielding layer and the position of the perforation in the outer layer. The same machine may be used to form the perforations in the outer layer and the openings in the shielding layer.

[0040] Alternatively, as discussed above, an opening large enough to correspond to at least one region configured to allow light transmission may be formed in the shielding layer, including at least one region of perforations arranged in one or more clusters, regions, or arrays. As discussed above, in the case where perforations are arranged in one or more clusters, regions, or arrays, a boundary portion without perforations may be arranged around each cluster, region, or array in the outer layer.

[0041] The shielding portion may be provided in the shielding layer corresponding to the border portion. The shielding portion may be provided in the shielding layer, preferably corresponding to the stitching in the outer layer. In such a configuration, the shielding layer will therefore preferably be provided as a layer having a series of openings and a series of connected shielding portions corresponding to the border portion in the outer layer (through which the stitching is preferably provided).

[0042] One preferred material for the obscuring layer is T5000 material available from West Bridgford Machines.

[0043] Although the shielding layer is preferably arranged to be cut into a shape and configuration corresponding to the configuration of the outer layer, the shielding layer can be formed using multiple smaller shielding layer parts to form the shielding layer. The use of smaller shielding layer parts can be used for smaller decorative structures or outer layers, with smaller border portions between clusters, areas or arrays of perforations.

[0044] A masking layer may be provided only relative to the stitching pattern.

[0045] The obscuring layer will preferably have a continuous covering on the outer layer, except at locations corresponding to the at least one perforation. Providing a single obscuring layer with a continuous covering (except where light is intended to pass) may make the obscuring layer easier to position and apply.

[0046] The shielding layer may be cut to a shape corresponding to the outer layer, with one or more extensions or tabs extending outwardly from the outer edge of the outer layer. Each of the one or more extensions or tabs may be provided with an opening or hole therethrough. The one or more extensions or tabs with openings or holes may be used to position the shielding layer relative to the outer layer on a press.

[0047] The use of extensions or tabs on the obscuring layer may help to properly align the obscuring layer with the outer layer.

[0048] The shielding layer will preferably be attached directly to the outer layer. The shielding layer may be attached directly to the "B" surface of the outer layer. Although any method may be used, adhesives may be preferred. Heat activated adhesives may be particularly preferred. Adhesives may be provided to the outer layer and / or the shielding layer.

[0049] The resiliently compressible spacer layer may be made of a material that diffuses light as it passes through it in use. In this embodiment, the spacer layer is operable in use to scatter light from the light source so that it is incident on a wide area of ​​the inner surface of the outer cover.

[0050] The spacer layer may have any thickness from 1.0 mm to 12.0 mm, but will preferably be from 3.0 mm to 6.0 mm thick.

[0051] The spacer layer can be cut into a shape corresponding to the desired shape of the decorative structure.

[0052] The spacer layer may be a fabric or foam. The outer surface of the spacer layer may be bonded to the inner surface of the at least partially opaque obscuring layer. Although any method may be used, an adhesive may be preferred. A heat activated adhesive may be particularly preferred. The adhesive may be provided to the obscuring layer and / or the spacer layer.

[0053] The spacer layer may be deformed to a reduced thickness corresponding to the stitching pattern. The deformed, reduced thickness spacer layer may be formed by compression of the spacer layer corresponding to the stitching pattern. Preferably, any deformation of the spacer layer corresponding to the stitching pattern will be permanent.

[0054] This can be achieved in a variety of ways, such as using a press. A press can be used to compress the spacer layer at a suitable temperature and / or pressure. A hot press can be used to compress the spacer layer at a suitable temperature and / or pressure. A hand roller can be used to compress the spacer layer at a certain temperature and / or pressure.

[0055] The press may have an upper (heated) tool with a raised pattern, in which case the raised pattern corresponds to the configuration of the outer layer. Preferably, the raised pattern corresponds to the configuration of the stitching pattern on the outer layer. The bottom tool of the press may be a flat plate. One or more vertical posts may be provided in the press relative to the bottom tool, and on the one or more vertical posts, the openings in the one or more extensions or tabs on the outer layer and the shielding layer are positioned to align the outer layer and the shielding layer.

[0056] In an embodiment, once the outer layer, the masking layer and the spacer layer are positioned in the press, the press is closed during the embossing step, causing the three layers to become adhered together and the spacer layer to plastically deform due to the raised area of ​​the top tool in the press. Thus, the spacer layer becomes compressed along the stitching lines, as if the spacer layer was quilted (attached to the outer layer by stitching), but without stitching through the spacer layer (or masking layer). At this stage, the A surface of the outer layer may still appear flat, and the texture will be on the back side (B surface) of the now connected three-layer decorative structure.

[0057] The spacer layer may be deformed prior to attachment to the obscuring layer and / or the outer layer.

[0058] Deforming of the spacing layer may be achieved simultaneously with or as a result of attaching the respective layers together.

[0059] The embossing step may be carried out at a temperature of 0° to 300°.

[0060] The embossing step may last from 10 to 120 seconds.

[0061] The embossing step may be carried out at a pressure of 0 to 10 bar.

[0062] The decorative structural component may be attached / adhered to the luminous / illuminable substrate.While any method may be used, spray adhesive may be preferred.

[0063] A vacuum process (similar to vacuum forming) can be used to attach a decorative structural component to a luminous / luminous substrate. In an embodiment, a cover layer is placed on the A surface of the decorative structural component and the luminous / luminous substrate located on the inner surface of the adjacent spacer layer (with adhesive between the two). Then, the decorative structural component can be pressed into contact with the adhesive and the luminous / luminous substrate. This can be performed by hand and / or using a tool. A specific pressure can be applied to the stitching pattern to ensure adhesion in those areas. Then a vacuum can be applied to keep the decorative structural component in close contact with the luminous / luminous substrate when the adhesive is cured. Heat or other mechanisms can be used to trigger adhesion or faster or effective curing. This keeps the inner surface of the spacer layer (which is deformed) in contact with the luminous / luminous substrate, so that the "quilted" texture becomes apparent on the A surface. Then, the deformed portion of the decorative structure is "lowered" on the A surface, and due to the thickness of the undeformed spacer layer, the remaining portion will rise on the A surface to produce a quilted effect. Other methods, such as applying pressure by hand or with a tool may be preferred.

[0064] The luminous / luminous substrate may be or include a light source. The light source may include a light plate having an inner major surface and an outer major surface directed toward the inner surface of the spacer layer. The light source may include a light guide positioned adjacent to an edge of the light plate, the light guide being operable in use to guide light transmitted along the light guide into the light plate. The inner major surface of the guide plate may be provided with a light reflecting layer for guiding light incident on the interior of the plate towards the outer major surface of the guide plate.

[0065] The light source may include at least one light emitting member. The light emitting member may be selected from a bulb, an LED and a laser. The light emitting member may be configured to emit white light or one or more colors of light. The light emitting member may be a white LED or an RGB LED. In the case where the light source includes a light panel, then in use at least one light emitting member may be arranged to direct light directly into the light panel.

[0066] Alternatively, where the light source comprises a light guide located adjacent an edge of the light panel, the light emitting member and light guide may be configured such that, in use, light emitted from the light emitting member enters and is transmitted along the light guide.

[0067] Alternatively, the light emitting member may be a light emitting film configured to emit light into the spacer layer in use.The light emitting film may be laminated to an inner surface of the spacer layer and / or may be an OLED.

[0068] In the case where the light source comprises a light guide, the decoration may be provided as a laminated decorative panel, wherein the spacer layer is laminated directly or indirectly to the outer main face of the light guide. In this embodiment, the light panel may be used as a support substrate for the decorative panel without providing an additional support substrate. Alternatively, the light panel may be fixed to a support substrate, which may be part of the vehicle structure, such as a door substrate, a body panel, a dashboard or a console.

[0069] In the case where the light emitting member is a light emitting film, the light emitting member may be attached to the supporting substrate on a side opposite to the spacer layer.

[0070] According to a fourth aspect of the present invention, there is provided a method for manufacturing a layered decorative structure, the method comprising the following steps:

[0071] providing a stitching pattern and at least one region in the outer layer configured to allow light transmission;

[0072] positioning a resiliently compressible spacer layer configured to allow light to be transmitted to the at least partially opaque obscuring layer so as to sandwich the at least partially opaque obscuring layer to the outer layer; and

[0073] The spacer layer is deformed to a reduced thickness corresponding to the stitching pattern.

[0074] The deformed, reduced thickness spacer layer may be formed by compression of the spacer layer corresponding to the stitching pattern.Preferably, any deformation of the spacer layer corresponding to the stitching pattern will be permanent. DETAILED DESCRIPTION

[0075] In order that the present invention may be more clearly understood, one or more embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0076] FIG. 1 is an isometric view of a prior art perforated, quilted trim structure for a vehicle panel having a stitched surface.

[0077] Figure 2 is a flow chart of a method according to an embodiment of the present invention.

[0078] Figure 3 is a schematic diagram of a decorative structure of an embodiment at a point in the method of an embodiment.

[0079] Figure 4 is a schematic side cross-sectional view of a decorative structure of an embodiment in which an opening is provided in the masking layer for each perforation.

[0080] Figure 5 It is shown Figure 5 Schematic side cross-sectional view of a decorative structure attached to a carrier.

[0081] Figure 6 is a schematic side cross-sectional view of a decorative structure of an embodiment in which an opening is provided in the masking layer for each perforated area.

[0082] Figure 7 It shows Figure 6 Schematic side cross-sectional view of a decorative structure attached to a carrier.

[0083] Figure 8 is a schematic side cross-sectional view of a quilted effect decorative structure of an embodiment in which an opening is provided in the masking layer for each perforation.

[0084] Fig. 9 It shows Figure 8 Schematic side cross-sectional view of a decorative structure attached to a carrier.

[0085] Fig.10 is a schematic side cross-sectional view of a quilted effect decorative structure of an embodiment, wherein an opening is provided in the masking layer for each perforated area.

[0086] Fig.11 It shows Fig.10 Schematic side cross-sectional view of a decorative structure attached to a carrier.

[0087] Fig.12a is an isometric view of the outer layer of an embodiment in place in a heat press.

[0088] Figure 12b The shielding layer is Fig.12a Axonometric view in place on the outer layer shown in .

[0089] Fig.12c yes Figure 12b An axonometric view of the spacer layer on the shielding layer shown in FIG.

[0090] Fig.12d yes Fig.12c The layers shown in FIG. 1 are an axonometric view after pressing.

[0091] Fig.13 is a view of a vehicle door with the trim structure assembly of an embodiment in place and illuminated.

[0092] According to a preferred embodiment, a layered decorative structure 50 is provided to give a quilted and stitched appearance similar to that illustrated in FIG. 1 .

[0093] In the prior art decorative structure shown in Figure 1, an outer perforated layer 10 of leather or the like is provided on a deformable substrate (not shown, on the underside). Stitching 11 is then used to attach the outer layer and substrate together, and the stitching 11 draws the deformable substrate closer to the outer layer 10 to create a quilted effect, as shown in Figure 1.

[0094] As in Figures 5 to 11 Schematically illustrated in Figures 12a to 12d In use, the layered decorative structure 50 of the preferred embodiment of the present invention includes an outer layer 10, which includes a stitching pattern 11 and a plurality of perforated areas that allow light transmission. An elastically compressible spacer layer 12 that is also configured to allow light transmission is positioned with an at least partially opaque shielding layer 13 disposed between the outer layer 10 and the spacer layer 12. The shielding layer 13 is provided with a plurality of openings corresponding to the locations of the perforated areas in the outer layer 10. The openings in the shielding layer are specifically Figure 12b As shown in the figure.

[0095] Preferably, the at least partially opaque shielding layer will effectively prevent light from passing except where openings are formed through the at least partially opaque shielding layer. Specifically, the at least partially opaque shielding layer may include at least one shielding portion corresponding to the stitching pattern of the outer layer.

[0096] This allows light to pass through the spacer layer 12 and through at least one area of ​​the perforations 16 so as to be visible, but prevents light that passes through the spacer layer 12 from passing through the opaque shielding portion provided by the shielding layer 13, in particular the stitching 11 in the outer layer 10. This allows a layered decorative structure to include a stitching pattern on the outer layer 10, but only allows light to pass through, wherein the opaque shielding layer 13 has an opening that in turn aligns with at least one perforated area. In particular, as Figure 5 and Figure 7 As shown, light can shine through the perforations 16 but not elsewhere.

[0097] Figures 4 to 11 The schematic diagram shown in is divided into Figures 4 to 7 and Figures 8 to 11 , Figures 4 to 7 shows a flat decorative structure without quilting effect, Figures 8 to 11 A decorative structure based on a 3D, quilted effect is shown.

[0098] As shown in FIG. 1 , more than one perforation may be provided in at least one perforated area 16 .

[0099] To simulate this effect in the preferred embodiment, each perforation 16 in the outer layer 10 can be aligned with a corresponding opening in the masking layer 13, such as Figure 4 , Figure 5 , Figure 8 and Fig. 9 as shown in .

[0100] Alternatively, if Figure 6 , Figure 7 , Fig.10 and Fig.11 As shown, the openings in the masking layer may be larger and may be aligned with the perforated area rather than with individual perforations 16. This may make alignment simpler given the larger area involved and light leakage from one perforation 16 through one or more adjacent perforations less of a problem.

[0101] like Fig.12a As shown, the outer layer 10 will preferably be cut into the shape required for the decorative structure. Cutting and perforating can be achieved in the same step or in different steps. A die cutting press can be used.

[0102] like Fig.12a As clearly shown in FIG. 1 , the outer layer 10 of the illustrated embodiment is provided with one or more extensions or tabs extending outwardly from its outer edge. Each of the one or more extensions or tabs is provided with an opening or hole therethrough. Fig.12a As shown, one or more extensions or tabs with openings or holes are used to position the outer layer relative to the lower plate of the press. The outer layer 10 is positioned so that the "A" surface is downward and the "B" surface is most upward. In the press, the masking layer 13 is directly placed on the "B" surface of the outer layer using adhesive between the layers.

[0103] As shown, the perforations are arranged in one or more clusters, regions or arrays. Where arranged in one or more clusters, regions or arrays, a border portion without perforations is preferably arranged around each cluster, region or array.

[0104] The stitching provided in the outer layer 10 may be embroidered into the outer layer 10. In one form, a CNC embroidery machine may be used.

[0105] The stitching preferably goes only into the outer layer. This is in contrast to the prior art decorative structure of Figure 1, where the stitching is applied through the outer layer and the base (spacer layer) to create a quilted effect.

[0106] like Figure 12b and Fig.12c As shown, an at least partially opaque shielding layer 13 is disposed between the outer layer 10 and the spacer layer 12. Figure 12b As shown, the masking layer 13 has a plurality of openings corresponding in position to the perforated areas in the outer layer 10 .

[0107] The obscuring layer 13 is preferably cut to a shape corresponding to the configuration of the stitching and perforated areas in the outer layer 10. The obscuring layer may be cut to shape using a die cutting press.

[0108] The same machine can be used to form the perforations in the outer layer 10 and the openings in the masking layer 13 .

[0109] In the illustrated embodiment, as discussed above, an opening is formed in the masking layer 13 that is large enough to correspond to each perforated area provided in one or more clusters, areas or arrays, with a border portion in the outer layer having no perforations provided around each cluster, area or array. Stitching 11 is provided into the outer layer 10 at the border portion.

[0110] The shielding portions are arranged in the shielding layer corresponding to the border portions. In this configuration, the shielding layer 13 will therefore preferably be arranged as a layer having a series of openings and a series of connected shielding portions, which correspond to the border portions in the outer layer 10 through which the seams 11 are arranged.

[0111] like Figure 12b As shown in , the obscuring layer will preferably have a continuous covering on the outer layer 10 except in the locations corresponding to the perforations 16 .

[0112] like Figure 12b As shown in , the shielding layer 13 is preferably cut to correspond to the shape of the outer layer 10, wherein one or more extensions or tabs extend outwardly from its outer edge. Each extension or tab is provided with an opening or hole passing therethrough. One or more extensions or tabs with openings or holes are used to position the shielding layer 13 relative to the outer layer 10 on the press. The use of extensions or tabs on the shielding layer 13 can help the shielding layer 13 to be correctly aligned with the outer layer 10.

[0113] The obscuring layer 13 will preferably be attached directly to the outer layer 10. The obscuring layer 13 is shown attached directly to the "B" surface of the outer layer 10 using a heat activated adhesive provided to the outer layer 10 and / or the obscuring layer 13.

[0114] The resiliently compressible spacer layer 12 may be made of a material that diffuses light when it passes through it in use. In this embodiment, the spacer layer 12 is operable in use to scatter light from the light source so that the light is incident on a wide area of ​​the inner surface of the outer cover 10.

[0115] The spacer layer 12 may be cut into shapes to correspond to the desired shape of the decorative structure.

[0116] The spacer layer may be fabric or foam. The outer surface of the spacer layer 12 may be bonded to the inner surface of the at least partially opaque obscuring layer 13. Although any method may be used, heat activated adhesives may be particularly preferred. Adhesives may be provided to the obscuring layer 13 and / or the spacer layer 12.

[0117] like Figures 8 to 11As shown in , the spacer layer can be deformed to a reduced thickness in the area 18 corresponding to the stitching pattern. The deformed, reduced thickness spacer layer 12 can be formed by compression of the spacer layer 12 corresponding to the stitching pattern. Preferably, the deformation of the spacer layer corresponding to the stitching pattern is a permanent deformation.

[0118] The deformation can be achieved in a variety of ways, such as using a press. A press can be used to compress the spacer at a suitable temperature and / or pressure. A hot press can be used to compress the spacer at a suitable temperature and / or pressure. A hand roller can be used to compress the spacer at a certain temperature and / or pressure.

[0119] like Figures 12a to 12d As shown, the press may have an upper (heated) tool 19 having a raised pattern, which in this case corresponds to the configuration of the outer layer 10. Preferably, the raised pattern corresponds to the configuration of the stitching pattern on the outer layer 10. As shown, the bottom tool 20 of the press may be a flat plate. One or more vertical posts may be provided in the press relative to the bottom tool, and on the vertical posts, the openings in the one or more extensions or tabs on the outer layer 10 and the shielding layer 13 are positioned to align the outer layer 10 and the shielding layer 13.

[0120] exist Figures 12a to 12d In the embodiment shown, once the outer layer 10, the masking layer 13 and the spacer layer 12 are positioned in the press, the press is closed during the embossing step, causing the three layers to become adhered together and the spacer layer 12 to be plastically deformed by the raised areas of the top tool in the press. The spacer layer thus becomes compressed along the seams, as if the spacer layer were quilted (attached to the outer layer by seams 11) but without seams 11 passing through the spacer layer 12 (or masking layer 13). At this stage, the A surface of the outer layer 10 may still appear flat and the texture will appear as shown in FIG. Fig.12d On the back side (B surface) of the now connected three-layer decorative structure shown in .

[0121] In this embodiment, deformation of the spacer layer 12 is achieved simultaneously with or as a result of attaching the respective layers together.

[0122] The embossing step may be carried out at a temperature of 0° to 300°.

[0123] The embossing step may last from 10 seconds to 120 seconds.

[0124] The embossing step may take place at a pressure of 0 to 10 bar.

[0125] like Figure 5 , Figure 7 , Fig. 9 and Fig.11As shown, the decorative structural assembly may then be attached / adhered to the luminous / illuminable substrate 15. Although any method may be used, spraying the adhesive 14 may be preferred.

[0126] exist Fig. 9 and Fig.11 In the embodiment, the decorative structure component is attached to the luminous / luminescent substrate 15. In this embodiment, the cover layer is placed on the A surface of the decorative structure component and the luminous / luminescent substrate 15 located on the inner surface of the adjacent spacer layer 12 (with adhesive 14 between the two). Then, the decorative structure component can be pressed on the luminous / luminescent substrate 15, for example by hand, especially applying pressure along the stitching line / pattern, so that the adhesive 14 is formed. A vacuum is then applied so that the reduced atmosphere forces the decorative structure component to be in close contact with the luminous / luminescent substrate 15 to keep the decorative structure component in place on the luminous / luminescent substrate 15 while the adhesive is cured. Heat is also used to cure the adhesive more quickly or efficiently. This keeps the inner surface of the spacer layer 12 (its deformation 18) in contact with the luminous / luminescent substrate 18, and the effect is that the "quilted" texture becomes apparent on the A surface. Then, the deformed portion of the decorative structure is "lowered" on the A surface, and due to the thickness of the undeformed spacer layer, the remaining portion will be raised on the A surface to produce a quilted effect.

[0127] The luminescent / luminescable substrate may be or include a light source including at least one luminescent member or a luminescent film configured to emit light into the spacer layer. The luminescent film may be laminated to the inner surface of the spacer layer and / or may be an OLED.

[0128] When light is emitted, the light is directed into and through the spacer layer 12 and through the perforations 16 in the outer layer 10 without passing through the shielding layer 13 .

[0129] exist Figure 2 The method for manufacturing the layered decorative structure is also shown in the form of a flow chart. The method comprises the following steps:

[0130] 1. Cut the outer layer of the decorative structure into shape.

[0131] 2. The outer layer, usually hide, is shaved (cut to a uniform thickness, preferably 0.6mm to 1.2mm). Other materials may be used. Shaving may not be necessary.

[0132] 3. The outer layer is perforated and cut so that the tabs around its outer edge each have a hole (laser cut). These tabs are used to position the outer layer during CNC embroidery (step 4) and on the lamination / embossing press step 7 (A surface down, B surface up).

[0133] 4. The perforated outer layer is then stitched as desired using a CNC embroidery machine. This differs from regular sewing where stitching is applied through the leather and base to create a quilted effect.

[0134] 5. Cut the opaque masking layer using a press. The particular material used is one that is commonly used for seam sealing on waterproof fabrics. This is die cut in accordance with the perforated outer layer. The material is coated with a heat activated adhesive on one side and is cut to have locating tabs in accordance with the perforated outer layer and placed adhesive side down on the outer layer on the press. The opaque material contains openings that correspond to the perforated areas in the outer layer.

[0135] 6. The spacer layer is then placed over the opaque masking layer. The spacer layer is plastically deformable and is also a good light emitter. The spacer layer is also coated with a heat activated adhesive and placed adhesive side down over the opaque masking layer.

[0136] 7. In this embodiment, lamination and embossing are achieved simultaneously in a laminating / embossing press. The press has an upper (heated) tool with a raised pattern, which in this case corresponds to the desired diamond pattern stitching on the leather as shown in Figure 1. The press is closed so that the three layers become adhered together and the spacer layer is plastically deformed by the raised areas of the top tool in the press, the bottom tool being a flat plate. The spacer layer thus becomes compressed along the stitching lines, as if it were quilted, but without stitching through the spacer layer (or masking layer). However, in reality, at this stage, the A surface will still appear flat and all the texture will be on the back (B surface).

[0137] This step can be accomplished in a variety of ways, such as using a welding machine or a hand roller.

[0138] 8. The completed assembly is then adhered to the luminous / illuminable substrate using a spray adhesive in a vacuum process (similar to vacuum forming). The cover layer is placed on the A surface. The decorative structural assembly is then pressed onto the luminous / illuminable substrate 15 by hand, particularly applying pressure along the stitching lines / patterns so that the adhesive 14 is formed in contact. A vacuum is then applied to keep the underside of the decorative structural assembly in close contact with the luminous substrate while the adhesive cures. Heat is used to help cure the adhesive. This forces the spacer layer into contact with the substrate, with the effect that a "quilted" texture becomes apparent on the A surface because these deformed portions of the spacer layer (corresponding to the stitching on the A surface) are lower than the undeformed portions on the A surface of the assembly, giving the appearance of a "quilted" texture.

[0139] Processing parts a, b and c correspond to Figure 3 The configuration shown in .

[0140] Fig.13An illuminated trim structure 50 of an embodiment is shown mounted in a door of a vehicle. Fig.13 The 3D quilting effect on the decorative structure 50 is shown, as well as light passing through the perforations 16 in the perforated area, while no light passes through the stitching pattern 16 .

[0141] One or more embodiments have been described above by way of example only. Many variations are possible without departing from the scope of protection provided by the appended claims.

Claims

1. A layered decorative structure, include: an outer layer comprising a stitching pattern and at least one region configured to allow light transmission; an elastically compressible spacer layer configured to allow light transmission; and an at least partially opaque shielding layer disposed between the outer layer and the spacer layer, the shielding layer being configured to have at least one opening corresponding in position to the at least one region configured to allow light transmission.

2. The layered decorative structure according to claim 1, in, The at least partially opaque obscuring layer effectively prevents the passage of light except where openings are formed through the at least partially opaque obscuring layer.

3. The layered decorative structure according to claim 1 or 2, in, The at least one area configured to allow light transmission includes at least one perforation through the opaque outer layer.

4. The layered decorative structure according to claim 3, in, More than one perforation is provided in at least one perforation region in the outer layer.

5. The layered decorative structure according to claim 4, in, Each perforation is aligned with a corresponding opening in the masking layer.

6. The layered decorative structure according to claim 4, in, The openings in the obscuring layer are aligned with each of the at least one perforated areas in the outer layer.

7. A layered decorative structure according to any one of the preceding claims, in, The outer layer is provided with one or more extensions or tabs extending outwardly from an outer edge of the outer layer.

8. The layered decorative structure according to claim 7, in, Each of the one or more extensions or tabs is provided with an opening or aperture therethrough.

9. A layered decorative structure according to any one of the preceding claims, in, The stitching pattern is stitched into the outer layer.

10. A layered decorative structure according to any one of the preceding claims, in, The obscuring layer is shaped to correspond to the configuration of the stitching pattern into the outer layer and at least one area configured to allow light transmission.

11. A layered decorative structure according to any one of the preceding claims, in, The shielding layer has at least one opening, and the at least one opening corresponds in position to the at least one region configured to allow light transmission.

12. The layered decorative structure according to claim 11, in, The at least one opening in the obscuring layer is large enough to correspond to at least one area configured to allow light transmission, the at least one area configured to allow light transmission comprising at least one perforated area arranged in one or more clusters, areas or arrays.

13. The layered decorative structure according to claim 12, in, At least one masking portion is provided in the masking layer corresponding to the stitching pattern in the outer layer.

14. A layered decorative structure according to any one of the preceding claims, in, The shielding layer includes one or more extensions or tabs extending outwardly from an outer edge of the shielding layer.

15. The layered decorative structure according to claim 14, in, Each of the one or more extensions or tabs is provided with an opening or aperture therethrough.

16. A layered decorative structure according to any one of the preceding claims, in, The obscuring layer is directly attached to the outer layer.

17. A layered decorative structure according to any one of the preceding claims, in, The spacing layer is directly attached to the shielding layer.

18. A layered decorative structure according to any one of the preceding claims, in, Prior to assembly, the spacer layer is embossed to deform the spacer layer to a reduced thickness in at least one area corresponding to the stitching pattern on the outer layer.

19. An illuminated vehicle trim comprising a layered trim structure according to any preceding claim and a light source operable, in use, to direct light through the spacer layer to the outer covering to be visible through the at least one region configured to allow light transmission.

20. A method for manufacturing a layered decorative structure, the method The following steps are involved: A stitching pattern and at least one area configured to allow light transmission are provided in an outer layer, an at least partially opaque shielding layer including at least one opening is positioned relative to the outer layer so that the at least one opening in the shielding layer corresponds in position to the at least one area configured to allow light transmission in the outer layer, and an elastically compressible spacer layer configured to allow light transmission to the at least partially opaque shielding layer is placed to clamp the at least partially opaque shielding layer to the outer layer.

21. The method of making a layered decorative structure of claim 20, further comprising the step of deforming the spacer layer to a reduced thickness corresponding to the stitching pattern.

22. The method of manufacturing a layered decorative structure according to claim 21, in, A deformed, reduced thickness spacer layer is formed by compressing the spacer layer corresponding to the stitching pattern.

23. A method of manufacturing a layered decorative structure according to claim 21 or claim 22, in, The deformation of the distance layer is achieved simultaneously with or as a result of attaching the respective layers together.

24. The method for manufacturing a layered decorative structure according to any one of claims 20 to 23, further comprising: The following steps are involved: The respective layers are pressed together using a heat press having at least one raised portion corresponding to the stitching pattern in the outer layer to hold the layered decorative structure together and plastically deform the spacer layer corresponding to the stitching pattern.

25. The method for manufacturing a layered decorative structure according to any one of claims 20 to 23, further comprising: The following steps are involved: The decorative structural assembly is held relative to the luminous / illuminable substrate using a vacuum process to maintain the inner surface of the spacer layer in contact with the luminous / illuminable substrate so that a quilted texture becomes apparent on the outer surface of the outer layer.

26. A method for manufacturing a layered decorative structure, the method The following steps are involved: providing a stitching pattern and at least one region in the outer layer configured to allow light transmission; placing a resiliently compressible spacer layer configured to allow light to be transmitted to the at least partially opaque obscuring layer to sandwich the at least partially opaque obscuring layer to the outer layer; and deforming the spacer layer to a reduced thickness corresponding to the stitching pattern.

27. The method of manufacturing a layered decorative structure according to claim 26, in, A deformed, reduced thickness spacer layer is formed by compressing the spacer layer corresponding to the stitching pattern.

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