Molded part and method for producing a molded part

Abstract

The invention relates to a molded part and a method of manufacturing a molded part. The molded part (10) comprises: a decorative layer (11) having a decorative layer front surface (12) configured as a viewing surface of the molded part (10) and a decorative layer back surface (13) opposite the decorative layer front surface (12); a carrier (14) arranged on the decorative layer rear side (13) and having a carrier front side (15) facing the decorative layer rear side (13) and a carrier rear side (16) opposite the carrier front side (15); and one or more light sources (17) arranged at the carrier rear side (16) and / or in the carrier (14) and / or between the decorative layer rear side (13) and the carrier (14) for backlighting the decorative layer (11). The invention is characterized in that the carrier (14) is formed at least partially from a natural substance (18). The invention further relates to a method for producing such a molded part.

Description

[0001] The invention relates to a molded part and a method for producing a molded part. The molded part is in particular a decorative part (also called trim part) and / or an interior trim part of a vehicle interior which is designed as a molded part.

[0002] A large number of decorative and interior parts (eg, door trims, consoles, and instrument panels) are installed in the interior space of a vehicle. The decorative and interior parts also include operating buttons or their cover parts.

[0003] These molded parts include: a decorative layer having a front side of the decorative layer configured as a visible surface of the molded part and a back side of the decorative layer opposite to the front side of the decorative layer; a carrier arranged on the back side of the decorative layer, having a front side of the carrier facing the back side of the decorative layer and a back side of the carrier opposite to the front side of the carrier; and one or more light sources arranged at the back side of the carrier and / or in the carrier and / or between the back side of the decorative layer and the carrier for backlighting the decorative layer.

[0004] Known carriers are constructed to be transparent or translucent, for example, by injection molding with transparent or translucent plastics. Thus, the carrier can be penetrated by light emitted from a light source arranged at or in the back of the carrier, and thus reach the back of the decorative layer, thereby backlighting the decorative layer.

[0005] Natural substances (e.g., wooden layers of wooden layer structures) or bio-based materials (e.g., natural fiber-reinforced plastics) as carrier materials are usually not transparent or translucent enough to allow the light from the light source arranged at or in the back of the carrier to pass through the carrier to the back of the decorative layer. In the case of wooden layer structures, the inherent color of the two or more wooden layers and / or the adhesive (e.g., bioadhesive) used to connect the wooden layers prevents this. In the case of natural fiber-reinforced plastics, the inherent color of the material that is difficult to transmit light and / or the high fiber content prevent this. Nevertheless, it is still desirable to use such natural substances as carrier materials in molded parts.

[0006] The object of the present invention is therefore to provide a novel molded part, in particular a sustainable molded part, ie a molded part with the lowest possible CO2 footprint and a backlit decorative layer. In addition, a method for producing the molded part should be provided.

[0007] This object is achieved with respect to the molded part by a molded part having the features of claim 1 and with respect to the method by a method having the features of claim 16. Advantageous embodiments and developments are given in the respective dependent claims.

[0008] The molded part according to the present invention comprises: a decorative layer having a front side of the decorative layer configured as a visible surface of the molded part and a back side of the decorative layer opposite to the front side of the decorative layer; a carrier arranged on the back side of the decorative layer, the carrier having a front side of the carrier facing the back side of the decorative layer and a back side of the carrier opposite to the front side of the carrier; and one or more light sources arranged at the back side of the carrier and / or in the carrier and / or between the back side of the decorative layer and the carrier for backlighting the decorative layer.

[0009] The invention provides that the carrier is at least partially (i.e. partially or completely) formed from one or more natural substances. In particular, the carrier is mainly or completely formed from one or more natural substances. For example, the carrier is at least 90%, in particular at least 95%, formed from one or more natural substances, wherein the percentages are based on weight.

[0010] The advantages of the invention are in particular that natural substances are used as carrier materials and that backlighting of the decorative layer is nevertheless possible.

[0011] The molded part is, in particular, a decorative part (also called trim part) and / or an interior trim part designed as a molded part for the interior of a vehicle.

[0012] According to a variant embodiment, the decorative layer can be a light-transmitting decorative layer. For example, the material of the decorative layer itself can be light-transmitting. Alternatively or additionally, the decorative layer can have a recess and / or a through hole and / or a light channel for allowing light to pass through.

[0013] For example, the decorative layer may comprise or consist of a wood laminate and / or a plastic (for example manufactured by means of IML (Film Insert Molding) or FIM (Film Insert Molding) or IMD (In-Mold-Decoration)) and / or a film and / or a fabric and / or a textile layer and / or a fabric and / or a carbon and / or a stone layer and / or a slate layer and / or a marble layer.

[0014] It can be provided that a transparent or translucent protective layer and / or an appearance layer is arranged on the front side of the decorative layer, wherein the protective layer and / or the appearance layer comprises, for example, lacquer or polyurethane (PUR) or plastic, or is formed by lacquer or polyurethane (PUR) or plastic. In order to arrange the protective layer and / or the appearance layer made of PUR or plastic on the front side of the decorative layer, the PUR or plastic is preferably poured onto the front side.

[0015] A design scheme of the present invention stipulates that the natural material of carrier is wood, and carrier is a wood layer structure, and this wood layer structure comprises two or more wood layers connected to each other on the face respectively via layer structure adhesive layer.The adhesive of layer structure adhesive layer can be for example a bio-adhesive (that is, bio-based adhesive substance).The example of suitable bio-adhesive is resin, for example liquid resin, particularly sprayable resin, or for example a resin as adhesive film.Also can use other adhesives as alternatives of bio-based adhesive substance.

[0016] According to an embodiment of the present invention, the natural substance of the carrier is a bio-based material. The bio-based material can be, for example, a natural fiber reinforced plastic, such as natural fiber reinforced polypropylene (abbreviation: NFPP). The natural fiber used for reinforcement can be, for example, flax fiber and / or industrial hemp fiber and / or kenaf fiber and / or sisal fiber.

[0017] If one or more light sources are arranged between the back side of the decorative layer and the carrier, the following improvements can be made: One or more light sources can be applied to the front side of the carrier, for example the front side of a wood layer or an adhesive layer or the front side of an NFPP. For example, one or more light sources can be LEDs applied to the front side of the carrier, for example directly by embossing and / or applied to one or two or more adhesive layers by embedding. One or more light sources can also be a luminescent adhesive layer, for example an adhesive layer using a luminescent additive, which is applied to the front side of the carrier. A mask (for example an embossed mask) can be arranged between one or more light sources (for example one or more LEDs and / or a luminescent adhesive layer) and the back side of the decorative layer in order to only partially backlight the decorative layer. Electrical contacting of one or more light sources can be made between the back side of the decorative layer and the front side of the carrier, for example by means of conductive strips and / or conductive wire bundles and / or flexible strips and / or pigtails led out from the molding between the back side of the decorative layer and the front side of the carrier and / or by means of through-holes in the carrier between the front side of the carrier and the back side of the carrier, through which conductive strips and / or conductive wire bundles and / or flexible strips and / or pigtails can be laid and led out from the molding on the back side of the carrier.

[0018] The improvement scheme of the present invention provides that one or more light sources are arranged at and / or in the carrier back side.In addition, the carrier has one or more through holes between the carrier back side and the carrier front side for transmitting light of one or more light sources to the back side of the decorative layer.

[0019] In particular, this development has the advantage that a natural substance can be used as carrier material and still allow light from one or more light sources to penetrate the carrier in order to backlight the decorative layer.

[0020] The design of the present invention provides that one or more light sources are arranged in one or more through holes of the carrier and / or at one or more through holes on the back of the carrier. It can also be provided that one or more light sources are embedded in a transparent or translucent plastic in or at a through hole. The transparent or translucent plastic in which the one or more light sources are embedded can at least fill one or more through holes in the carrier and thus form a light guide passing through the carrier. For example, a plurality of through holes filled with transparent or translucent plastic can be provided, wherein the through holes can be connected to each other on the back of the carrier by a plastic layer formed of transparent or translucent plastic. The plastic layer can be arranged on the back of the carrier partially or over the entire surface.

[0021] The one or more light sources may be, for example, LEDs.

[0022] If a plurality of light sources are provided, they can be connected to one another to form a light source network or light source grid. The individual sources can then be assigned to individual through-holes, in particular inserted into the through-holes or arranged at the beginning of the through-holes on the back side of the carrier.

[0023] A development provides that one or more light sources are electrically connected via contacts arranged on the rear side of the carrier.

[0024] According to a design, the decorative layer and the carrier are connected to each other via a decorative adhesive layer, in particular a transparent or translucent decorative adhesive layer. The decorative adhesive layer can be formed by a bioadhesive (ie a bio-based adhesive substance, such as a resin).

[0025] According to a further development, a partial or full surface layer made of bio-based plastic can be attached as an additional carrier layer to the back of the carrier. This layer can be produced by back-spraying with bio-based plastic particles. With this layer, the required rigidity and / or breaking strength and / or splitting resistance of the molded part can be achieved, which properties may not be fully guaranteed without this layer.

[0026] The method according to the invention for producing the above-mentioned molded part according to the invention comprises the following steps:

[0027] a) providing or producing a decorative layer and a carrier at least partially consisting of a natural substance,

[0028] b) Arranging one or more light sources at the rear side of the carrier and / or in the carrier and / or between the rear side of the decorative layer and the carrier.

[0029] The advantages of the method according to the invention result from the above explanations concerning the molded part according to the invention.

[0030] The decorative layer and the carrier can be produced together. The carrier can be sprayed onto the decorative layer, wherein, for example, bioplastic particles can be used. However, the decorative layer and the carrier can also be produced separately, wherein in this case, the decorative layer can be bonded to the carrier.

[0031] The improvement provides that one or more light sources are arranged at the back side of the carrier and / or in the carrier, and one or more through holes in the carrier are formed between the back side of the carrier and the front side of the carrier. In particular, it can be provided that one or more light sources are arranged in one or more through holes and / or at one or more through holes on the back side of the carrier.

[0032] In the method according to the invention, it can be provided according to a further development that one or more through holes in the carrier are produced by punching and / or milling and / or laser processing and / or etching. Punching and / or milling and / or laser processing and / or etching can be carried out, for example, before or after reconstruction of the carrier or a carrier already provided with a decorative layer. In the case of laser processing when a decorative layer is already attached to the carrier, the laser processing is carried out from the back of the carrier, wherein, in order to avoid changes in the decorative layer due to the laser processing, a barrier layer which is transparent to visible light but cannot be burned by the laser used is arranged and / or formed between the decorative layer and the carrier.

[0033] It can also be provided that one or more through-holes are back-sprayed with a transparent or translucent plastic, wherein the one or more through-holes are filled with the transparent or translucent plastic and one or more light sources are embedded in the transparent or translucent plastic. It can be provided that before the back-spraying, the one or more light sources are previously fixed in their position in or on the carrier.

[0034] Alternatively, it can also be provided that the lighting element comprising one or more light sources is first manufactured by embedding the one or more light sources in a transparent or translucent plastic, and the one or more light sources are subsequently arranged in or at one or more through holes by inserting the lighting element into the one or more through holes.

[0035] According to a further development, a partial or full surface layer made of bio-based plastic can be attached as an additional carrier layer to the back of the carrier. This layer can be produced by back-spraying with bio-based plastic particles. With this layer, the required rigidity and / or breaking strength and / or splitting resistance of the molded part can be achieved, which properties may not be fully guaranteed without this layer. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Other features and advantages of the present invention will be described in more detail below based on the description of the embodiments and with reference to the attached schematic diagrams.

[0037] Figure 1a schematic cross-sectional view showing a portion of a first embodiment of a molded part according to the invention; and

[0038] Figure 2 A schematic sectional view shows a detail of a second exemplary embodiment of a molded part according to the invention.

[0039] Corresponding parts and components are also denoted by the same reference numerals in different exemplary embodiments.

[0040] Figure 1 and Figure 2 Embodiments of decorative and / or interior trim parts for vehicle interiors configured as molded parts 10 according to the present invention are shown respectively. The molded part 10 comprises a decorative layer 11 having a decorative layer front side 12 configured as a visible surface of the molded part 10 and a decorative layer back side 13 opposite to the decorative layer front side 12. A carrier 14 is bonded to the decorative layer back side 13 via a decorative adhesive layer 30, which can be formed of a bioadhesive (i.e., a bio-based adhesive substance), wherein the carrier has a carrier front side 15 facing the decorative layer back side 13 and a carrier back side 16 opposite to the carrier front side 15. According to Figure 2 As an alternative to bonding with the decorative adhesive layer 30 , the carrier 14 can also be sprayed onto the decorative layer back 13 .

[0041] In addition, the molded part 10 includes a plurality of light sources 17 (three light sources 17 are shown in the figure). These light sources 17 are symbolically represented, arranged at the back side 16 of the carrier, and are used to backlight the decorative layer 11, that is, the light emitted from the light source 17 illuminates the back side 13 of the decorative layer. The light source 17 can be, for example, an LED.

[0042] The light sources 17 can be designed individually and inserted into the molded part 10. In the exemplary embodiment shown, however, the light sources are connected to one another to form a light source network 28. During the production of the molded part 10, this light source network 28 can already be attached to the carrier back 16 and the individual light sources can be positioned at or in the through-holes 19 in the carrier 14. The electrical connection of the light sources 17 is accomplished by Figure 1 and Figure 2 This is achieved by an electrical contact 29 , which is indicated by dashed lines in FIG. 2 and is arranged on the carrier rear side 16 .

[0043] exist Figure 1 In the first embodiment shown, the carrier 14 is formed from a natural substance 18 , more precisely from a bio-based material 23 , in particular from a natural fiber reinforced plastic 24 , such as natural fiber reinforced polypropylene (abbreviation: NFPP).

[0044] exist Figure 2In the second embodiment shown, the carrier 14 is a wooden layer structure 20, which has a plurality of wooden layers 22 (specifically four wooden layers 22 are shown) as a natural material 18, and these wooden layers 22 are bonded to each other on the surface via a layer structure adhesive layer 21 (specifically three layer structure adhesive layers 21 between four wooden layers 22 are shown). Therefore, in this second embodiment, the carrier 14 is also at least partially formed by natural substances. The adhesive of the layer structure adhesive layer 21 can be a bioadhesive, that is, a bio-based adhesive substance. In addition, in the second embodiment shown, an additional layer structure adhesive layer 21 terminating the wooden layer structure 20 is arranged on the back side 16 of the carrier, and the additional layer structure adhesive layer 21 is used, for example, to connect additional layers, such as the plastic layer 27 further described below. In an alternative design scheme, the additional layer structure adhesive layer 21 on the back side 16 of the carrier can also be omitted.

[0045] The natural fiber reinforced plastic 24 of the first embodiment and the wood layer structure 20 of the second embodiment are both opaque or at least not sufficiently transparent to achieve the above-mentioned backlighting of the decorative layer 11. Therefore, in order to achieve this, in both embodiments, the carrier 14 has a plurality of through holes 19 (specifically three through holes 19 are shown) between the carrier back 16 and the carrier front 15 to transmit light from the light source 17 to the decorative layer back 13.

[0046] The light source 17 is arranged at the through-hole 19 on the carrier back side 16. The light source 17 can also be arranged in the through-hole 19. The light source 17 is embedded in a transparent or translucent plastic 25, which fills the through-hole 19 in the carrier 14 and thus forms a light guide 26 through the carrier 14. In addition, the through-holes 19 at the carrier back side are connected to each other by a plastic layer 27 formed by the transparent or translucent plastic 25. In the embodiment shown, the plastic layer 27 extends partially on the carrier back side 16, but the plastic layer 27 can also alternatively cover the entire carrier back side 16.

[0047] As Figure 1 and Figure 2 As an alternative to the illustrated embodiment, the light source 17 can also be arranged between the decorative layer rear side 13 and the carrier 14 (not shown).

[0048] Figure 1 and Figure 2 The illustrated embodiment of the molded part 10 according to the invention can be produced, for example, by the following steps:

[0049] First, the decorative layer 11 and the corresponding carrier 14 are produced and / or provided. The decorative layer 11 and the carrier 14 can be produced together. The carrier 14 can be sprayed onto the decorative layer 11, wherein, for example, bioplastic particles can be used. However, the decorative layer 11 and the carrier 14 can also be produced separately, wherein in this case, the decorative layer 11 can be bonded to the carrier 14. Then, the through-holes 19 are introduced into the carrier 14, for example by punching or milling or laser processing. Alternatively, this can also be done before the decorative layer 11 is applied. If necessary, the carrier 14 and / or the decorative layer 11 can be reconstructed before or after the decorative layer 11 is applied to the carrier 14 and / or before or after the through-holes 19 are introduced.

[0050] The light source 17 can be embedded in the transparent or translucent plastic 25 by first arranging the light source 17 at the desired position at or in the through hole 19, fixing the light source 17 there in advance if necessary, and then injecting the transparent or translucent plastic 25 into the back of the through hole 19. Here, the through hole 19 is filled with the transparent or translucent plastic 25. The plastic layer 27 is also formed in the back injection process. The transparent or translucent plastic 25 can be a bio-based plastic, but it can also be a conventional plastic.

[0051] Alternatively, the lighting element including the light source 17 can also be manufactured by first embedding the light source 17 in a transparent or translucent plastic 25, and then the embedded light source 17 can be arranged in or at the through hole 19 by inserting the lighting element into the through hole 19. If the lighting element is designed appropriately, in particular after molding, the through hole 19 is also filled with a transparent or translucent plastic 25, and a plastic layer 27 is arranged on the carrier back side 16. The lighting element is fixed on the carrier back side 16, for example, by a layer structure adhesive layer 21.

[0052] Reference Mark List

[0053] 10 Molded parts

[0054] 11 Decorative layer

[0055] 12 Decorative layer front

[0056] 13 Decorative layer back

[0057] 14 Carrier

[0058] 15 Carrier front

[0059] 16 Carrier back side

[0060] 17 Light Source

[0061] 18 Natural substances

[0062] 19 Through Holes

[0063] 20 Wood layer structure

[0064] 21 layers of structural adhesive

[0065] 22 wooden layer structure 20 wooden layer

[0066] 23 Bio-based materials

[0067] 24 Natural fiber reinforced plastics, especially NFPP

[0068] 25 Transparent or translucent plastics

[0069] 26 Light Guide

[0070] 27 Plastic layer

[0071] 28 Light Source Network

[0072] 29 Contact

[0073] 30 Decorative adhesive layer.

Claims

1. A molded part (10), comprising: a decorative layer (11) having a decorative layer front side (12) configured as a visible side of the molded part (10) and a decorative layer rear side (13) opposite the decorative layer front side (12), a carrier (14) arranged on the back side (13) of the decorative layer, the carrier (14) having a carrier front side (15) facing the back side (13) of the decorative layer and a carrier back side (16) opposite to the carrier front side (15); and one or more light sources (17), the one or more light sources (17) being arranged at the back side (16) of the carrier and / or in the carrier (14) and / or between the back side (13) of the decorative layer and the carrier (14) for backlighting the decorative layer (11), It is characterized in that The carrier (14) is at least partially formed from one or more natural substances (18).

2. The molded part (10) according to claim 1, characterized in that The natural substance (18) of the carrier (14) is wood, and the carrier is a wooden layer structure (20) comprising two or more wooden layers (22) which are connected to one another on the surface via a layer structure adhesive layer.

3. The molded part (10) according to claim 1, characterized in that The natural substance of the carrier is a bio-based material (23).

4. The molded part (10) according to claim 3, characterized in that The bio-based material (23) is a natural fiber reinforced plastic (24).

5. The molded part (10) according to claim 4, characterized in that The natural fiber reinforced plastic (24) is natural fiber reinforced polypropylene (NFPP for short).

6. The molded part (10) according to any one of the preceding claims, characterized in that The one or more light sources (17) are arranged at the back side (16) of the carrier and / or in the carrier (14), and the carrier (14) has one or more through holes (19) between the back side (16) and the front side (15) of the carrier for transmitting light from the one or more light sources (17) to the back side (13) of the decorative layer.

7. The molded part (10) according to claim 6, characterized in that The one or more light sources (17) are arranged in the one or more through holes (19) of the carrier (14) and / or are arranged at the one or more through holes (19) on the carrier back side (16).

8. The molded part (10) according to claim 7, characterized in that The one or more light sources (17) are embedded in a transparent or translucent plastic (25) in or at the through hole (19).

9. The molded part (10) according to claim 8, characterized in that The transparent or translucent plastic (25) embedding the one or more light sources (17) fills at least the one or more through holes (19) in the carrier (14) and thus forms a light guide (26) passing through the carrier.

10. The molded part (10) according to claim 9, characterized in that A plurality of through holes (19) filled with the transparent or translucent plastic (25) are provided, wherein the through holes (19) are connected to one another on the back side (16) of the carrier via a plastic layer (27) formed of the transparent or translucent plastic (25).

11. The molded part (10) according to any one of the preceding claims, characterized in that The one or more light sources (17) are LEDs.

12. The molded part (10) according to any one of the preceding claims, characterized in that A plurality of light sources (17) are provided, which are interconnected to form a light source network (28) or a light source web.

13. The molded part (10) according to any one of the preceding claims, characterized in that The one or more light sources (17) are electrically connected via contacts (29) arranged on the carrier rear side (16).

14. The molded part (10) according to any one of the preceding claims, characterized in that The decorative layer (11) and the carrier (14) are connected to each other via a decorative adhesive layer (30).

15. The molded part (10) according to any one of the preceding claims, characterized in that A partial or full surface layer made of bio-based plastic is attached to the back side (16) of the carrier.

16. A method for producing a moulding (10) according to any one of the preceding claims, the method comprising the steps of: a) providing or producing the decorative layer (11) and the carrier (14) at least partially formed from a natural substance (18), b) Arranging the one or more light sources (17) at the back side (16) of the carrier and / or in the carrier (14) and / or between the back side (13) of the decorative layer and the carrier (14).

17. The method according to claim 16, further comprising the steps of: The one or more light sources (17) are arranged at the carrier back side (16) and / or in the carrier (14), and One or more through holes (19) are produced in the carrier (14) between the carrier back side (16) and the carrier front side (15).

18. The method according to claim 17, further comprising the steps of: The one or more light sources (17) are arranged in the one or more through-holes (19) and / or at the one or more through-holes (19) on the carrier back side (16).

19. The method according to claim 17 or 18, wherein the following steps are further provided: The one or more through holes (19) in the carrier (14) are produced by punching and / or milling and / or laser machining and / or etching.

20. The method according to any one of claims 17 to 19, further comprising the following steps: The one or more through holes (19) are back-sprayed with a transparent or translucent plastic (25), wherein the one or more through holes (19) are filled with the transparent or translucent plastic (25) and the one or more light sources (17) are embedded in the transparent or translucent plastic (25).

21. The method according to claim 20, further comprising the steps of: The one or more light sources (17) are pre-fixed prior to the back spraying.

22. The method according to any one of claims 17 to 19, further comprising the following steps: a1) manufacturing a lighting element comprising the one or more light sources (17) by embedding the one or more light sources (17) in a transparent or translucent plastic (25), and a2) arranging the one or more light sources (17) in or at the one or more through holes (19) by inserting the lighting element into the one or more through holes (19).

23. The method according to any one of claims 16 to 22, wherein: A partial or full surface layer made of bio-based plastic is attached to the back side (16) of the carrier.

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