Molded trim part manufacturing method, molded trim part and motor vehicle charging station

Abstract

The invention relates to a method for producing a cover for a molded decorative part of a motor vehicle, in particular for a charging station (2) of a mobile radio, to a molded decorative part of a motor vehicle, and to a charging station for inductive charging of a terminal for a motor vehicle, in which method a decorative layer (24) is inserted into a mold (54), the invention relates to a method for producing a decorative layer (24) having at least one perforation (42) extending from a rear side (26) of the decorative layer (24) to a visible surface (22) of the decorative layer (24) and having a soft elastic plastic layer on the rear side (26), in which method the rear side (26) of the decorative layer (24) is back-injected with a carrier plastic material (40) to form a carrier (38) such that the projections (44) are formed from the soft elastic plastic layer (30), the projection protrudes beyond the visible side surface on the visible side and is supported in a shaped manner by a cured carrier plastic material (40).

Description

Technical Field

[0001] The invention relates to a method for producing a decorative molded part for a motor vehicle, in particular a cover for a charging station for mobile phones, a molded decorative part for a motor vehicle and a charging station for inductively charging a terminal for a motor vehicle. Background Art

[0002] Such molded decorative parts are often used for the interior trim of motor vehicles. A common method involves back-injecting a decorative layer with a plastic material, which serves as a carrier for securing the molded decorative part in the motor vehicle. The decorative layer can be coated on the visible side, for example by overmolding the visible side in a two-component injection molding process, with the decorative layer serving as an insert in the injection mold. Summary of the Invention

[0003] The underlying problem of the present invention is to provide a method for producing a molded decorative part that is particularly suitable for covering a charging station for a mobile phone in a motor vehicle. Furthermore, the present invention aims to provide a corresponding molded decorative part. The present invention also provides a charging station for a motor vehicle, which is intended for inductively charging a terminal device.

[0004] In the method according to the present invention, a charging station cover is produced by first providing a decorative layer having at least one opening. The decorative layer has a rear side, which is provided for attachment to the carrier, and a visible side, which characterizes or defines the decorative appearance within the vehicle. The visible side surface of the decorative layer can be formed from any decorative design, such as veneer, leather, plastic (particularly plastic with a carbon appearance), metal, etc. The decorative layer typically has a substantially flat, two-dimensional extent. The decorative layer is typically relatively thin.

[0005] The perforations extend from the back of the decorative layer to the visible side surface. A soft, elastic plastic layer is provided on the back of the decorative layer. Adhesive and / or fleece may be provided between this plastic layer and the decorative layer. These additional layers are particularly useful for attaching the soft, elastic plastic layer to the decorative layer. If additional layers are provided between the decorative layer and the soft, elastic plastic layer, these layers will typically also be perforated.

[0006] However, according to the present invention, the soft elastic plastic layer is not only located behind the decorative layer. It extends through the decorative layer and, in the area of ​​at least one perforation, protrudes beyond the visible side surface of the decorative layer. The soft elastic plastic layer forms a protrusion that prevents objects placed on the covering from slipping. The soft elastic plastic layer can be formed from thermoplastic elastomer (TPE), polyester, or thermoplastic polyurethane (TPU). Typically, molded decorative parts have a carrier formed from a solidified carrier plastic material. In the present invention, this carrier plastic material is injected behind the decorative layer. It should be understood that at least the soft elastic plastic layer is located between the carrier plastic material and the decorative layer. The solidified carrier plastic material provides shape support for the protrusion, which extends beyond the visible side surface on the visible side and is formed by the soft elastic plastic extending through the perforation. This means that the solidified carrier plastic material and the plastic material of the soft elastic plastic layer are regularly located within the perforation, and at least a partial area of ​​the soft elastic plastic layer protrudes beyond the visible side surface, possibly also forming part of the solidified carrier plastic material.

[0007] During the molding process in the mold (usually an injection mold), the mold part is placed against the visible side of the decorative layer. This creates a cavity in the area of ​​the opening. This cavity is dimensioned so that the soft, resilient plastic layer protrudes above the visible side surface of the decorative layer. The shape of this cavity determines the cross-sectional shape of the protrusion. The protrusion typically has a convex surface or end face that is generally flush with the visible side surface of the decorative layer at the edge of the perforation.

[0008] Where the invention is based on the visible side surface of the decorative layer, this can also be formed by a paint finish or other application on the substrate that essentially forms the decorative layer. For example, a single board can be provided with a layer of paint that maintains the color fastness of the wood grain during the service life of the molded decorative part.

[0009] The protrusion can be formed by a soft elastic plastic layer which is pushed out on the visible side surface by the injection pressure acting during back injection.

[0010] Alternatively or additionally, the soft-elastic plastic layer can be deformed in the direction of the visible side surface by means of a forming die before being inserted into or within the mold. This preforming step of the soft-elastic plastic layer is particularly desirable when a large number of perforations are arranged closely together, which may require deformation of the soft-elastic plastic layer at different points. The soft-elastic plastic layer may not be sufficiently capable of following deformations beyond the visible side surface. For these reasons, the soft-elastic plastic layer can already be brought into its final protruding form or at least partially reformed in the direction of this form by forming, in particular plastic deformation, before back-injection with the carrier plastic material, so that the subsequent injection molding with the carrier plastic material only needs to achieve a certain portion of the total deformation of the soft-elastic plastic layer.

[0011] Conventional methods can be used to create the openings, such as stamping, cutting, or laser cutting. This processing of the decorative layer is usually performed on the single sheet, at least after the color has been applied. Only then is the soft, elastic plastic layer laminated, and the intermediate product produced in this way is then formed into a three-dimensional preform, which is then placed in a mold to form the carrier. The back of the injected intermediate product may then need to be milled. If the chosen decorative layer makes this necessary or desirable for design reasons, the visible side surface of the decorative layer can then be painted.

[0012] The decorative layer can be provided with a perforation pattern. The pattern can be a regular perforation pattern, which can be designed, for example, as a symbol or as ribs or waves. The perforations can be designed as a logo corresponding to the vehicle manufacturer's imprint or brand.

[0013] If the molded trim part has several projections, these can each have the same or different designs, in particular cross-sectional shapes.

[0014] If necessary, the final painting of the decorative layer should in particular be done with a paint that has good adhesion to the surface of the decorative layer but poor or no adhesion to the surface of the soft elastic plastic material, so that the paint is not permanently located on the protrusions and its tactile properties are determined by the material of the soft elastic plastic.

[0015] The method according to the invention is also suitable for molding decorative parts other than charging station covers. For example, it is conceivable to use protrusions to provide tactile markings whose meaning can be felt. It is also conceivable within the scope of the invention to design the perforations so that the protrusions cause information to be reproduced in Braille.

[0016] The protrusions typically extend 0.1 mm to 2.0 mm above the visible side surface of the decorative layer.

[0017] The protrusions can also have a decorative effect. The protrusions can be opaque and / or colored in any color. In the case of a transparent or translucent soft elastic plastic layer, the layer located behind the soft elastic plastic layer can be visible from the visible side behind the soft elastic plastic layer and can contribute to the decorative appearance of the molded decorative part.

[0018] Considering the use of the decorative layer as a cover for a charging station for inductively charging terminal devices, the molded decorative part as a whole should have a thickness of only between 1.5 mm and 4.5 mm. Below the storage surface for the terminal device formed by the molded decorative part of the present invention, there is an inductive charging device whose magnetic field must pass through the molded decorative part and reach the terminal device. To this end, the molded decorative part should not exceed this thickness.

[0019] According to a second aspect of the present invention, a decorative molding comprises a decorative layer provided with at least one perforation extending from a visible side surface of the decorative layer to a rear side opposite the visible side surface. A soft, elastic plastic material is interspersed within the perforation. The soft, elastic plastic material forms a coating on the rear side of the decorative layer and a protrusion opposite the coating. The protrusion extends over the visible side surface of the decorative layer, and the soft, elastic plastic material is connected to a carrier at the rear side. As described above, the carrier typically also extends through the plane containing the decorative layer and may extend beyond the plane on the visible side.

[0020] According to a preferred further development of the present invention, the molded decorative part is suitable for conveying optical information in darkness. To this end, the molded decorative part includes a light source that interacts light-conductively with a light-conducting element or segment disposed on the surface of the covering. According to a specific embodiment of this basic proposal, the soft, elastic plastic is formed as a light guide. Thus, the soft, elastic plastic itself is suitable for guiding light as a light conductor. The soft, elastic plastic can be, for example, transparent, translucent, or possibly colored TPE, polyester, or thermoplastic polyurethane (TPU). In this design, the light-conducting soft, elastic plastic is typically positioned between two non-light-conducting layers, which, for example, act as adhesion promoters, bonding the soft, elastic plastic to the decorative layer on the one hand and to the carrier on the other. As mentioned above, this does not exclude the presence of an additional intermediate layer, which can also be opaque. This design ensures that the soft, elastic plastic is perceived only as a light element located on the visible surface of the decorative layer. In addition to protrusions, the soft, elastic plastic can also form surface portions on the surface of the covering, or be visible as recessed surface elements or surface elements that are flush with the visible side surface of the decorative layer. In the first case, the molding tool can include a molding tool part that provides a cavity for the protrusion and a lens profile for the light-conducting section, which engages in a light-conducting opening recessed in the decorative layer. When the soft, elastic plastic is molded, for example, it is pushed into the light-conducting opening and shaped in a predetermined manner by the lens profile. The lens profile can have any desired shape.

[0021] In the second case, it is sufficient for the molded part to form only an opposite surface in continuation of the contact surface of the decorative layer, against which the soft elastic plastic material is molded to form a light guide flush with the visible side surface of the decorative layer.

[0022] According to a preferred embodiment of the present invention, the molded decorative part preferably has ventilation openings extending therethrough. This further development is guided by the idea that, in the case of a charging station for inductively charging terminal devices in a motor vehicle, not only is the charging device located below the storage surface, but also a blower, which cools the charging device and / or the terminal devices placed on the storage surface. It will be appreciated that several such charging openings may be provided, preferably arranged so that the cooling air flow covers the terminal to be heated over as large an area as possible.

[0023] The ventilation opening is preferably located at the transition between the projection and the decorative layer. The ventilation opening can follow the contour of the phase boundary between the projection and the decorative layer. The ventilation opening can extend over the entire edge of the projection or on both sides of the projection. This is particularly advantageous if the decorative layer is subsequently provided with a lacquer layer after the projection has been formed. This lacquer layer ends at a predetermined end at the ventilation opening on the visible side.

[0024] The ventilation openings can be formed completely after the back injection of the carrier and the removal of the resulting intermediate product. However, the ventilation openings can also be formed in various layers of the molded decorative part before the back injection of the carrier and in other layers after or during the back injection of the carrier. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Further details and advantages of the present invention will become apparent from the following description of embodiments in conjunction with the accompanying drawings. The accompanying drawings show:

[0026] Figure 1 is a schematic diagram of an embodiment of a charging station,

[0027] Figure 2 is a schematic cross-sectional view of an embodiment using an example decorative molding for a storage surface of a terminal,

[0028] Figure 3 is a schematic cross-sectional view of the mold. DETAILED DESCRIPTION

[0029] In the figures, reference numeral 2 denotes a charging station in a motor vehicle for inductively charging a terminal 4, which is depicted on a storage surface 6 and above an inductive charging device 8. Reference numeral 10 denotes a blower, which is also located below the storage surface 6, so that the air generated by the blower 10 cools the inductive charging device.

[0030] The storage surface 6 is formed by a molded trim part 12 provided with ventilation openings 14 through which the air generated by the blower 10 flows to the terminal device 4 and can cool it.

[0031] Reference numeral 16 denotes a light source interacting with a light guide 18 , as will be explained in more detail below, since it is part of the molded trim part 12 .

[0032] like Figure 2 As shown in the enlarged view in FIG, the molded decorative part 12 comprises several layers extending substantially parallel to one another. From the outside inward, these layers are a lacquer layer 20 disposed on a visible side surface 22 of a decorative layer 24. Reference numeral 26 denotes the rear side of the decorative layer 24, which is provided with a thermoplastic bonding agent 28 that bonds a soft elastic plastic layer 30 made of a soft elastic plastic 32 to the decorative layer 24.

[0033] On the rear side 26 of the soft elastic plastic layer 30 facing away from the decorative layer 24, there is a further thermoplastic adhesive 34 which connects the soft elastic plastic layer 30 to the fleece 36. Attached to the fleece 36 is a carrier 38 which consists of a carrier plastic material 40 which is a predominantly thermoplastic hard component.

[0034] In this example, a carrier 38 is shown schematically. On its rear side 26, facing away from the decorative layer 24, the carrier may have fastening means for connecting the molded decorative part 12 to a part of a motor vehicle, for example latching lugs or other designs forming a complementary molded surface for connection to the chassis of the vehicle.

[0035] exist Figure 2 In the embodiment, reference numeral 42 denotes an opening 42 into which the carrier plastic material 40 and the layers typically disposed between the decorative layer 24 and the carrier are introduced. The soft, elastic plastic 42 forms a projection 44, which is held in shape by a plug 46 of the carrier plastic material protruding into the opening. In the example shown, the projection 44 extends above the visible side surface 22 of the decorative layer 24. The same applies to the area in front of the plug 46.

[0036] like Figure 1 As shown, the terminal 4 rests on projections 44. These projections are formed from a soft, resilient plastic, so that the terminal 4 is secured against slipping. In the example shown, the soft, resilient plastic has light-conducting properties and is coupled to the light source 16 as a light-conducting element 18. Reference numeral 47 denotes a light-conducting opening in which the soft, resilient plastic 32 forms a flush or concave light-conducting element 48, thus forming an element that is recessed relative to the visible side surface 22. The soft plastic 32 located in the light-conducting opening 47 does not act as an anti-slip covering, but merely as a light-conducting design element.

[0037] Figure 3An intermediate step in the production of molded decorative part 12 is shown, in which a preform 52 is placed in a mold 54 comprising a first upper mold part 56 and a second lower mold part 58. Preform 52 comes into contact with the surface of upper mold part 56. This mold part 56 forms a flat contact surface 60 against which the substantially flat visible side surface 22 of preform 52, formed by decorative layer 24, bears. A lens profile 62 of mold part 56 projects from this flat contact surface 60 and engages in light guide opening 47. Reference numeral 64 denotes a cavity formed by mold part 56, opposite opening 42, and having a profile corresponding to the surface geometry of protrusion 44.

[0038] Figure 2 Shown are examples of projections 44 with different cross-sectional geometries. The left projection 44.1 has a strictly convex cross-sectional shape. The left projection 44.1 completely overlaps the paint layer 20. The right projection 44.2 rises from the annular surface area of ​​the soft elastic plastic layer 30, which is formed flush with the paint layer 20 and is formed flat on its end face. Correspondingly, the mold part 56 has cavities 64.1 and 64.2 of corresponding design.

[0039] Figure 3 The preform 52 shown is produced by first selecting a single sheet as the decorative layer 24 and applying a color layer to it. The perforations 42, light-guiding openings 47, and ventilation openings are then cut using a laser. The decorative layer 24 is laminated from a soft, elastic plastic layer 30, containing a thermoplastic adhesive 28 on one side and another adhesive 34 with a fleece 36 on the other. The intermediate product thus produced is then formed into the preform 52. The other layers 28, 30, 34, and 36 are also perforated at the level of the ventilation openings 14.

[0040] After the two mold parts 56, 58 are closed, a carrier cavity 66 is formed on the back side 26 of the fleece layer 36, facing away from the decorative layer 24, into which the molten carrier plastic material 40 is injected. The resulting injection pressure pushes the soft-elastic plastic layer 30 in the direction of the contact surface 60, so that the lens contour 62 forms a concave light-guiding element in the light-guiding opening 47, and the protrusion 44 is formed in the cavity 64. The flush structure 48 is formed by contact with the flat contact surface 60. The carrier plastic material solidifies and accordingly supports the soft-elastic plastic material, giving it shape.

[0041] Reference numeral 68 designates a tool projection located in the carrier cavity 66 , by means of which a region of reduced wall thickness is formed on the molded decorative part 12 , which region can be used for inductive charging electromagnetic waves to penetrate in an improved manner.

[0042] A paint layer 20 is then applied. This paint layer does not adhere to the soft elastic plastic layer 30, so that any paint residue can be blown off insofar as this paint layer 20 is not intended to cover the visible side surface 22 of the decorative layer 24. The invention makes it possible to form a molded decorative part 12 with a low wall thickness, so that the end device 4 placed on the storage surface 6 can be effectively inductively charged. The protrusion 44 secures the end device 4 to prevent it from slipping on the storage surface 6. The light guide opening 47 enables a further optional decoration of the decorative molded part 12, in particular an optical design that can also be recognized in the dark. The ventilation opening 14 prevents the end device 4 from overheating during inductive charging and effectively discharges the cooling air that cools the inductive charging device.

[0043] Reference Signs List

[0044] 2 Charging Stations

[0045] 4 End devices

[0046] 6 Storage Surface

[0047] 8 Inductive charging device

[0048] 10 Blower

[0049] 12 Molded decorative parts

[0050] 14 ventilation openings

[0051] 16 Light Source

[0052] 18 Light guide

[0053] 20 paint layers

[0054] 22 Visible side surfaces

[0055] 24 decorative layers

[0056] 26 rear side

[0057] 28 Thermoplastic Adhesion Promoter

[0058] 30 soft elastic plastic layer

[0059] 32 soft elastic plastic

[0060] 34 Adhesive

[0061] 36 Fiber wool

[0062] 38 carriers

[0063] 40 Carrier plastic material

[0064] 42 Opening

[0065] 44 protrusion

[0066] 46 Plug

[0067] 47 Light transmission opening

[0068] 48 Flush light guide components

[0069] 50 concave light-transmitting element

[0070] 52 Preforms

[0071] 54 mold

[0072] 56 mold parts

[0073] 58 mold parts

[0074] 60 contact surface

[0075] 62 Lens Profile

[0076] 64 cavity

[0077] 66 Carrier Cavity

[0078] 68 mold protrusion

[0079] L Airflow

Claims

1. A method for producing a decorative molded part for a motor vehicle, in particular a cover for a charging station (2) for a mobile phone, in which method a decorative layer (24) is inserted into a mold (54), the decorative layer being provided with at least one perforation (42) extending from a rear side (26) of the decorative layer (24) to a visible side surface (22) of the decorative layer (24), and on which a soft elastic plastic layer (30) is provided, the rear side (26) of the decorative layer (24) being back-injected with a carrier plastic material (40) to form a carrier (38), so that a projection (44) is formed by the soft elastic plastic layer (30), the projection (44) protruding on the visible side above the visible side surface (22) and being supported in a shaped manner by the solidified carrier plastic material (40).

2. The method according to claim 1, wherein The decorative layer (24) is prepared as a single sheet provided with a thermoplastic adhesive (28) and then provided with the at least one perforation (42).

3. The method according to claim 1, wherein The soft elastic plastic layer (30) is pushed beyond the visible side surface (22) by the injection pressure acting during back injection molding.

4. The method according to claim 1, wherein The soft elastic plastic layer (30) is deformed in the direction of the visible side surface (22) by a forming die before being inserted into the die (54).

5. The method according to claim 1, wherein The decorative layer (24) is prepared with a perforation pattern (42).

6. The method according to claim 1, wherein The decorative layer (24) provided with the plastic layer (30) is prepared to have a thickness between 0.2 mm and 0.4 mm.

7. A molded decorative part (12) for a motor vehicle, in particular a cover (12) for a charging station (2) for a mobile radio device, comprising a decorative layer provided with at least one perforation (42) extending from a visible side surface (22) of the decorative layer (24) to a rear side (26) opposite the visible side surface, through which a soft elastic plastic forms a coating on the rear side (26) of the decorative layer (24) and forms a projection (44) opposite the coating, the projection extending over the visible side surface of the decorative layer (24), and the soft elastic plastic being connected to a carrier (38) on the rear side.

8. The molded decorative part (12) according to claim 7, wherein The soft elastic plastic forms a light guide (18) connected to a light source (16).

9. The molded trim part (12) of claim 7, further comprising at least one ventilation opening (14) through the molded trim part (12).

10. A charging station (2) for inductively charging a terminal (4) for a motor vehicle, the charging station comprising a storage surface (6) for the terminal and an inductive charging device arranged below the storage surface (6), characterized in that The storage surface (6) is formed by a molded decorative part (12) according to claim 7.

11. The charging station (2) according to claim 10, wherein The at least one protrusion (44) forms an anti-slip support for the terminal (4).

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