Component having optical fibre and optical coupling device, and method for producing component

Abstract

The invention relates to a component comprising a fabric layer into which one or more optical fibers are woven, and at least one light coupling device via which light can be coupled into the optical fibers. The component is characterized in that the optical coupling means comprise a translucent injection-molded first plastic component, and in that the end of the optical fiber is embedded therein by means of a material bond. The invention also relates to a method for manufacturing the component, comprising the steps of: providing a fabric layer having one or more optical fibers woven therein, where the ends of the optical fibers protrude from the fabric layer; inserting the fabric layer into a first injection mold and overmolding the end of the optical fiber with a translucent first plastic component to form a material bond between the end of the optical fiber and the first plastic component; and forming the first plastic part into an optical coupling device via which light can be coupled into the optical fiber.

Description

Technical Field

[0001] The invention relates to a component, in particular a decorative part for vehicle interior, comprising a fabric layer in which optical fibers are woven, and to a method for manufacturing the component. Background Art

[0002] Components made of light-conducting fabrics are known in the prior art. Such components can be used in particular for decorative purposes, for example as a decorative outer cladding of a device. For example, decorative parts with light-conducting fabrics are used to cover the interior of vehicles. Light-conducting fabrics usually consist of a flat carrier material, for example a textile fabric, into which fibers of a light-conducting material are woven. The light-conducting fibers are configured in such a way that not only do the light-conducting fibers transmit light in the longitudinal direction, but light is also coupled to the fibers in the transverse direction. In this way, the fabric can be widely illuminated. The transverse coupling of light can be produced by appropriate surface treatment and / or fiber doping and by selecting appropriate bending radii.

[0003] An example of a component with a light-conducting fabric is disclosed in DE 20 2012 013 105 A1. The component comprises a multi-layered textile fabric, wherein optical fibers for light emission are provided in a first layer, and a second layer adjacent to the first layer is configured as a protective layer. In this case, the optical fibers are made of, for example, polymethacrylate, polystyrene or polycarbonate.

[0004] Another example of a textile fabric with a light-conducting fabric is disclosed in DE 10 2007 018 227 A1. This fabric comprises a carrier material and a plurality of light-conducting fiber bundles, which are attached to the carrier material via at least one thread. In one embodiment, the layered structure is embedded in a translucent carrier, in particular laminated or molded in a translucent carrier. The light-conducting fibers are preferably formed by glass fibers.

[0005] A disadvantage of making woven or knitted fabrics with optical fibers is their connection to the light source. In some cases, the optical fibers must be manually integrated into the device and fixed to the optical coupling elements. This process is disadvantageous in terms of cost and is accompanied by a high error rate. In addition, the connection between the light source and the actual illuminated fabric requires some space, as the bending radius must be maintained.

[0006] Technical issues

[0007] The present invention describes a possibility of remedying the above-mentioned disadvantages and of being able to produce such a component economically. Therefore, the object of the present invention is to provide a component with a light-conducting fabric which enables a simple coupling between the optical fibers of the light-conducting fabric and an external light source. Furthermore, the object of the present invention is to provide a method by which such a component can be produced at low cost, in large quantities and with high precision. Summary of the invention

[0008] The above mentioned problem is solved by a component and a method for producing the component according to the independent claims.

[0009] The invention is based on the basic idea of ​​forming an optical coupling device from an injection-molded plastic component, wherein the ends of the optical fibers of the light-conducting fabric are embedded in the material joint. In this way, light can be coupled into the optical fibers. Manufacturing the optical coupling device by overmolding the ends of the optical fibers with plastic material has proven to be a simple solution for fixing the optical fibers to the optical coupling device. In this way, the component according to the invention can be manufactured in large quantities with a low error rate. In addition, the injection molding process allows a great deal of flexibility in the shape, number and arrangement of the optical coupling devices.

[0010] part

[0011] The invention relates to a component, in particular a decorative part for a vehicle interior, comprising a fabric layer and at least one optical coupling device, wherein one or more optical fibers are woven into the fabric layer and light can be coupled into the optical fibers via the optical coupling device. The component is characterized in that the optical coupling device comprises a translucent injection-molded first plastic component and the end of the optical fiber is embedded in the first plastic component in a material-bonded manner.

[0012] For the purposes of the present invention, any material having a textile appearance can be used as the fabric layer into which the optical fibers can be woven. Thus, the fabric layer can include, for example, a woven fabric, interwoven yarns, a knitted fabric or a non-woven fabric into which the optical fibers are woven. The fabric layer can, for example, include natural fibers, synthetic fibers, glass fibers and metal fibers.

[0013] The production of a fabric layer into which one or more optical fibers are woven is basically known to the person skilled in the art. Such methods are disclosed, for example, in DE 10 2007 018 227 A1 and DE 10 2012 013 105 A1 and the references cited therein. However, no method is disclosed in the prior art that can couple an optical fiber to a light source in a simple manner.

[0014] In one embodiment, the component comprises at least one light source, which is connected to the optical coupling device in a light-conducting manner so that the light from the light source can be coupled into the optical fiber via the optical coupling device. The light source used is in particular an electric light source, preferably a light emitting diode (LED). The light source can, for example, optionally generate white light or colored light. The component can also have a plurality of light sources for generating light of different colors, such as a plurality of LEDs of different colors. In this case, the component preferably also has a control unit with which the different light sources can be selectively turned on and off so as to illuminate the component with different colors.

[0015] The optical fiber consists of a light-conducting material that can form a material bond with the first plastic component. Preferably, the optical fiber is made of plastic, especially preferably of a thermoplastic material. Suitable plastics for producing the optical fiber are, for example, polymethacrylate (PAAM), polystyrene (PS) or polycarbonate (PC). In a preferred embodiment, the optical fiber consists of polymethacrylate.

[0016] In order to make a material bond between the optical fiber end and the first plastic component, the melting point of the first plastic component and the melting point of the material of the optical fiber should match each other. Preferably, this means that the material of the first plastic component has a higher melting point than the material of the optical fiber.

[0017] The optical coupling device is mainly formed by the first plastic component which is injection molded. It is formed in such a way that light from the light source can be radiated into the optical coupling device. Since the end of the optical fiber is embedded in the first plastic component, light from the light source can be coupled into the optical fiber.

[0018] As explained below, the component can have a plurality of functionally independent optical coupling devices. This also requires a plurality of plastic components. In principle, within the scope of the invention, each plastic component can be connected to one or more optical fibers. However, preferably, each individual first plastic component is simultaneously connected to the ends of a plurality of optical fibers. Thus, a plurality of optical fibers are always combined into a group and each is connected as a group to an optical coupling device. Thus, the invention has the advantage that a plurality of optical fibers can be simultaneously connected to an optical coupling device in one injection molding step and a plurality of optical fibers can be connected to a light source in one step.

[0019] In one embodiment, the component comprises a plurality of optical fibers and a plurality of light coupling devices, each light coupling device being connected to a different optical fiber, so that light can be selectively coupled into one or more optical fibers via one or more light coupling devices. The ends of the individual optical fibers are therefore not embedded in a single uniform plastic component, but in functionally separate plastic components, each forming a separate light coupling device. In this case, the optical fibers can also be combined into a group and each connected to a light coupling device. With this embodiment, for example, only some of the optical fibers can be selectively illuminated, or different optical fibers can be illuminated, for example, with light of different colors from different light sources.

[0020] In this embodiment, the optical coupling devices are preferably functionally separated from each other so that light is coupled only via a specific optical coupling device into an optical fiber connected to the optical coupling device, without light being scattered into other optical fibers. This functional separation can be produced by spatially and / or optically separating the optical coupling devices. For example, the optical coupling devices can be spaced apart in such a way that light from one optical coupling device does not reach an adjacent optical coupling device. In addition, an opaque material layer can be provided between adjacent optical coupling devices to optically separate the optical coupling devices from each other.

[0021] Preferably, in this embodiment, the component has a plurality of light sources, each of which is assigned to a separate light coupling device and emits its light only into the correspondingly assigned light coupling device.

[0022] Preferably, the component in this embodiment also has a control unit, with which different light sources can be selectively switched on and off in order to selectively illuminate the individual light coupling devices and the optical fibers connected to them. Using this control unit, aesthetically interesting effects can be achieved by switching the individual optical fibers on and off in a time-controlled manner. For example, spatially adjacent optical fibers can be illuminated one after the other, so that animation effects can be achieved.

[0023] In a preferred embodiment, the component comprises a first set of substantially parallel optical fibers and a second set of substantially parallel optical fibers, wherein the optical fibers of the first set are arranged to cross the optical fibers of the second set, and wherein the optical fibers of the first set and the optical fibers of the second set are each connected to a different optical coupling device, so that light can be selectively coupled into the optical fibers of the first set and / or the optical fibers of the second set. Interesting fringe patterns can be generated using this embodiment.

[0024] In a further development of this embodiment, a group of essentially parallel optical fibers is also each connected to a different light coupling device, so that light can be coupled selectively into all optical fibers of a group and / or into individual optical fibers.

[0025] Due to its preferably flat structure, the fabric layer according to the invention has two opposite main surfaces, which in the context of the invention are referred to as the visible side and the carrier side. When the decorative part is used as intended, the visible side faces the observer, while the carrier side forms the side of the decorative part facing away from the observer. Furthermore, the fabric layer has side surfaces which are substantially at right angles to the above-mentioned main surfaces. The ends of the optical fibers protrude from the fabric layer in the direction of the side surfaces and are embedded in the plastic part of the optical coupling device.

[0026] The optical coupling means are preferably arranged along these side surfaces. In the context of the present invention, this arrangement is also referred to as being "lateral". In a preferred embodiment, the optical coupling means are arranged so as to laterally surround the fabric layer. In other words, the optical coupling means are arranged along all side surfaces and form a frame around the fabric layer. In this way, the optical coupling means also contribute to the mechanical stability of the decorative part.

[0027] Parts of the light coupling device can also be arranged on the carrier side of the component. In this way, light from a light source arranged on the carrier side can be coupled into the component.

[0028] The carrier side of the fabric layer is preferably fixed to a carrier plate. The carrier plate is made of plastic, for example, preferably made of translucent plastic. The fabric layer is preferably fixed to the carrier plate by means of an adhesive layer. The adhesive layer preferably covers the entire carrier side of the fabric layer.

[0029] According to a preferred embodiment of the invention, the carrier plate is made of a foam material, in particular a foam plastic material is used. The foam plastic material can be easily deformed and provides a relatively soft support for the carrying light guide. Therefore, in the event of an external force acting on at least one optical fiber, the optical fiber can generate this external force by moving backwards and entering the carrier, which will be deformed plastically and / or elastically. Therefore, the foam material will ensure an optimal light transmission through the optical fiber and avoid kinking of the fiber material in the event of external pressure acting on the light guide component.

[0030] In order to prevent damage to the fabric layer, the visible side of the fabric layer is preferably covered with a translucent plastic layer. The translucent plastic layer can be laminated to the fabric layer in the form of a film. Alternatively, the plastic layer can also be applied to the fabric layer by injection molding.

[0031] The component according to the invention is in particular a decorative part for the interior of a vehicle. For example, the component can be used as part of an interior decoration in a vehicle. For example, it can be used in motor vehicles, in particular cars and trucks, trains and airplanes. The component is particularly suitable as part of a dashboard, door trim or roof trim in a car interior. Furthermore, the component can also be used as a wall cladding in a building.

[0032] Manufacturing method

[0033] The present invention also relates to a method for manufacturing the above-mentioned component. The method comprises the following steps:

[0034] providing a fabric layer, wherein one or more optical fibers are woven into the fabric layer, wherein ends of the optical fibers protrude from the fabric layer;

[0035] inserting the fabric layer into a first injection mold and overmolding the end of the optical fiber with the translucent first plastic component to form a material bond between the end of the optical fiber and the first plastic component; and

[0036] The first plastic component is formed into a light coupling device, via which light can be coupled into the optical fiber.

[0037] The method according to the invention makes it possible to manufacture the component according to the invention cost-effectively and in large quantities. By overmolding the end of the optical fiber, a material bond between the end and the plastic component is ensured. In this way, the optical fiber and the plastic component are connected to one another in a light-conducting manner.

[0038] Preferably, the method according to the present invention comprises a further step, wherein the optical coupling device is connected to the light source in a light-conducting manner, so that light from the light source can be coupled into the optical fiber via the optical coupling device.

[0039] The temperature during overmolding of the end of the optical fiber is mainly based on the melting point of the first plastic component, which is injected into the injection mold in molten form. The temperature during overmolding is preferably higher than the melting point of the first plastic component. In order to promote the material bond between the first plastic component and the end of the optical fiber, the first plastic component is preferably injected at a temperature higher than the melting point of the material of the optical fiber. In this way, during overmolding, the end of the optical fiber is melted at least on the surface, so that the molten material of the optical fiber and the molten first plastic component flow into each other.

[0040] Preferably, the fabric layer is fixed to the carrier plate before being inserted into the first injection mold. The carrier plate is preferably a plastic plate. Preferably, before contacting with the fabric layer, the carrier plate is provided with an adhesive layer so that the fabric layer and the carrier plate can be bonded together. Alternatively, the adhesive layer can also be applied to the fabric layer before the fabric layer contacts the carrier plate.

[0041] In a preferred variant of the method, before overmolding with the first plastic part, the fabric layer is at least partially overmolded with a translucent second plastic part to form a translucent plastic layer, or is at least partially laminated with a film of the translucent second plastic part. In this way, a protective covering layer can be applied to the fabric layer. The overmolding with the second plastic part is preferably carried out in a different injection mold than the overmolding with the first plastic part. In this case, after overmolding with the second plastic part, the fabric layer is transferred from the first injection mold to the second injection mold.

[0042] The material of the second plastic component preferably has a higher melting point than the material of the first plastic component. In this way, during overmolding with the first plastic component, melting of the translucent plastic layer is prevented so that the optical coupling device and the translucent plastic layer do not adhere to each other. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] The present invention will be described in more detail below in conjunction with embodiments and with reference to the accompanying drawings. The present invention is represented in the drawings by the following parts:

[0044] Figure 1 It is a conventional component with a light-guiding fabric according to the prior art;

[0045] Figure 2 is an intermediate product for manufacturing a component according to the invention;

[0046] Figure 3 is an intermediate step in the manufacturing process according to the present invention;

[0047] Figure 4 is an intermediate step in the manufacturing process according to the present invention;

[0048] Figure 5 is a component according to a first embodiment of the present invention;

[0049] Figure 6 is a component according to a second embodiment of the present invention; and

[0050] Figure 7 is a component according to a third embodiment of the present invention. DETAILED DESCRIPTION

[0051] Figure 1 A conventional component with a light-conducting fabric according to the prior art is shown. The component comprises a fabric layer 1 of non-optical fibers 2, which is shown here in cross-section, and optical fibers 3 woven into it. For better visualization, only one optical fiber 3 is shown. In fact, the fabric layer 1 can also have a plurality of optical fibers 3, which can extend parallel to each other and / or diagonally. Similarly, the fabric layer 1 can have additional non-light-conducting fibers, which are connected to the non-light-conducting fibers. Figure 1The non-conductive optical fibers 2 schematically shown in FIG. 1 extend diagonally.

[0052] In this example, a fabric layer 1 consisting of fibers 2 and optical fibers 3 is attached to a translucent carrier plate 5 by means of an adhesive layer 4. The carrier plate thus defines the carrier side of the component.

[0053] according to Figure 1 The component of corresponds in principle to the component according to the invention in its structure, but no light coupling device is provided therein. Instead, the ends of the optical fibers 3 protruding laterally from the fabric layer 1 must be separately connected to the light source 8 in order to illuminate the optical fibers 3 .

[0054] Figure 2 Shows Figure 1 A variant of the component is shown, in which the component also has a translucent plastic layer 6, in which the fabric 1 is embedded. In the example shown here, the translucent plastic layer is an injection-molded plastic layer 6. Instead of an injection-molded plastic layer 6, a plastic film laminated to the fabric can also be used. The plastic layer 6 forms the visible side of the component and protects the fabric from damage. The ends of the optical fibers 3 protrude laterally from the composite of the fabric layer 1 and the plastic layer 6.

[0055] according to Figure 2 The component can be used as an intermediate product for manufacturing the component according to the invention. For this purpose, the end of the optical fiber 3 can be shortened to the desired length before being inserted into the first injection mold, wherein the end of the optical fiber 3 is overmolded with the translucent first plastic component.

[0056] Figure 3 Steps in a manufacturing method according to the present invention are shown. Figure 2 The component shown in FIG. 1 with the laterally protruding optical fibers 3 is inserted into an injection mold 9. The injection mold 9 forms a cavity into which the plastic component can be injection molded. The ends of the optical fibers 3 protruding from the component are arranged in this cavity in such a way that they can be overmolded with the plastic component. In the embodiment shown, the ends of the optical fibers 3 are arranged essentially parallel to the separation plane of the two-piece injection mold 9. The cavity defined by the injection mold 9 extends on the carrier side of the component and on the lateral outer circumference.

[0057] Figure 4 The manufacturing method according to the present invention is shown in which the first plastic component is injection molded into Figure 3 The following steps are shown in the injection mold 9. Figure 2The optical fiber 3 is a component which has been overmolded laterally and from the carrier side with a first plastic component. The end of the optical fiber 3 is embedded in the first plastic component by overmolding. In this way, the end of the optical fiber 3 is materially bonded to the first plastic component. Since the first plastic component consists of a translucent material, an optical coupling device 7 is formed in this way.

[0058] Figure 5 A first embodiment of a component according to the invention is shown. Figure 4 The component is obtained after demoulding from the injection mold shown. The component has an optical coupling device 7 made of an injection-molded first plastic component, in which the end of the optical fiber 3 is embedded with a material connection. The optical coupling device 7 surrounds the component laterally and on the carrier side. This makes it possible, for example, to illuminate the entire component by means of a light source 8 arranged on the carrier side.

[0059] The component further comprises an injection moulded plastic layer 6 in which the light-conducting textile layer 1 is embedded. The plastic layer 6 forms the visible side of the component and is flush with the light coupling means 7 so that a substantially smooth surface is formed on the visible side.

[0060] The light-guiding fabric fiber layer 1 includes Figure 1 3 and the non-light-conducting fibers 2 are shown in FIG. The fabric layer 1 is attached to a translucent carrier plate 5 by means of an adhesive layer 4. Since both the carrier plate 5 and the plastic layer 6 are translucent, some of the light coupled into the light coupling device 7 can illuminate the fabric 1 from the carrier side. This, combined with the optical fibers 3, which are also illuminated, can give the component an attractive appearance.

[0061] Figure 6 A second embodiment of a component according to the invention is shown, which is substantially similar to Figure 5 However, in contrast to the first embodiment, the plastic layer 6 is not flush with the light coupling device 7 but rather protrudes beyond the light coupling device 7 towards the visible side.

[0062] Figure 7 A third embodiment of a component according to the invention is shown in a top view from the visible side. In this embodiment, the component has a fabric layer 1 of crossed non-optical fibers 2, and interwoven and also crossed optical fibers 3. The ends of the optical fibers 3 protruding laterally from the fabric are each embedded in a first plastic part of an optical coupling device 7 by a material bond. However, in contrast to the embodiment shown above, the component according to this embodiment comprises not only one, but a plurality of spatially separated optical coupling devices 7. The optical coupling devices 7 are each connected only to a single optical fiber 3.

[0063] Since the optical coupling devices 7 are spatially separated from one another and are only connected to individual optical fibers 3, the optical fibers 3 can each be illuminated by a different light source 8. This makes it possible to selectively illuminate individual optical fibers 3. For example, using a method according to Figure 7 In the embodiment of the present invention, only the optical fibers 3 extending transversely or vertically in the figure can be illuminated. It is also possible to illuminate only the parallel optical fibers 3 individually. The light-conducting fabric can thus be illuminated in rows and / or columns. Animations can also be generated by sequentially switching the light sources 8 on and off. For example, a wave pattern can be generated by sequentially illuminating the optical fibers 3 extending in parallel.

[0064] Reference numerals list

[0065] 1 Light-guiding fabric layer

[0066] 2 Non-optical fiber

[0067] 3. Optical fiber

[0068] 4 Adhesive layer

[0069] 5 Carrier board

[0070] 6 plastic layers

[0071] 7 Optical coupling device

[0072] 8 Light Source

[0073] 9Injection mold

Claims

1. A component, in particular a decorative part for a vehicle interior, comprising a fabric layer (1) and at least one optical coupling device (7), one or more optical fibers (3) being woven into the fabric layer, and light can be coupled into the optical fibers (3) via the optical coupling device, characterized in that: The optical coupling device (7) comprises a translucent injection-molded first plastic component, and the end of the optical fiber (3) is embedded in the first plastic component through a material connection.

2. The component according to claim 1, comprising at least one light source (8), which is connected to the optical coupling device (7) in a light-conducting manner so that light from the light source (8) can be coupled into the optical fiber (3) via the optical coupling device (7).

3. The component according to claim 1, wherein The optical fiber (3) is made of plastic.

4. The component according to claim 1, wherein The material of the first plastic component has a higher melting point than the material of the optical fiber (3).

5. The component according to claim 1, wherein The component comprises a plurality of optical fibers (3) and a plurality of optical coupling devices (7), each optical coupling device being connected to a different optical fiber (3), so that light can be selectively coupled into one or more optical fibers (3) via one or more optical coupling devices (7).

6. The component according to claim 1, wherein The component comprises a first group of substantially parallel optical fibers (3) and a second group of substantially parallel optical fibers (3), wherein the optical fibers (3) of the first group are arranged to cross the optical fibers (3) of the second group, and wherein the optical fibers (3) of the first group and the optical fibers (3) of the second group are each connected to a different optical coupling device (7) so that light can be selectively coupled into the optical fibers (3) of the first group and / or the optical fibers (3) of the second group.

7. The component according to claim 1, wherein: The optical coupling device (7) laterally surrounds the fabric layer (1).

8. The component according to claim 1, wherein The component comprises a carrier plate (5) to which the textile layer (1) is fixed.

9. The component according to claim 1, wherein: The fabric layer (1) is at least partially overmoulded with a translucent plastic layer (6).

10. The component according to claim 1, wherein The textile layer (1) is at least partially laminated with a translucent plastic film.

11. The component according to claim 8, wherein The carrier plate (5) is made of foam plastic material.

12. A method of manufacturing a component according to the preceding claim, comprising the steps of: Providing a fabric layer (1) into which one or more optical fibers (3) are woven, wherein ends of the optical fibers (3) protrude from the fabric layer; Inserting the fabric layer (1) into a first injection mold and overmolding the end of the optical fiber (3) with a translucent first plastic component to form a material bond between the end of the optical fiber (3) and the first plastic component; and The first plastic component is formed into a light coupling device (7) via which light can be coupled into the optical fiber (3).

13. The method according to claim 12, wherein: The optical coupling device (7) is connected to the light source (8) in a light-guiding manner, so that light from the light source (8) can be coupled into the optical fiber (3) via the optical coupling device (7).

14. The method according to claim 13, wherein: The first plastic component is injection molded at a temperature higher than the melting point of the material of the optical fiber (3).

15. The method according to claim 13, wherein: The textile layer (1) is fixed on a carrier plate (5) before being inserted into the first injection mold.

16. The method according to claim 12, wherein: The textile layer (1) is at least partially overmoulded with a translucent second plastic component to form a translucent plastic layer (6) before being overmoulded with the first plastic component, or is at least partially laminated with a film of the translucent second plastic component.

17. The method according to claim 12, wherein: The textile layer (1) is at least partially laminated with a film of a second translucent plastic component.

18. The method according to claim 16 or 17, wherein: The material of the second plastic component has a higher melting point than the material of the first plastic component.

19. The method according to claim 15, wherein: A foamed plastic material is used as the carrier plate (5).

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