Method for producing a decorative element, decorative element and its use

Abstract

Method for producing a decorative element, wherein an embroidery pattern (3) is embroidered onto a carrier layer (2), the carrier layer (2) is then placed onto a carrier element (1), whereupon the carrier element (1) and the carrier layer (2) together with the pattern (3) are provided with a sealing layer (4), so that the carrier layer (2) is arranged between the carrier element (1) and the sealing layer (4), and the carrier layer (2) consists of a material which dissolves or becomes transparent in contact with the material of the sealing layer (4), wherein the carrier layer is brought into contact with the sealing layer so that the carrier layer dissolves or becomes transparent, wherein the carrier layer (2), in particular the nonwoven, comprises cellulose, viscose, synthetic fibers, thermoplastics, such as polyester, polyvinyl alcohol, polyolefins or polyamides or consists of one of these materials or mixtures thereof, and wherein the sealing layer (4) is formed by a liquid plastic, wherein the carrier layer (2) is pressed onto the carrier element (1) by means of a vacuum-based introduction method, which comprises placing a membrane (7) and a boundary film (8) arranged thereover on a side of the carrier element (1) carrying the carrier layer (2) and subsequently generating a vacuum between the boundary film (8) and the carrier element (1) or the carrier layer (2), and wherein a water- or resin-soluble protective film (6) is arranged between the carrier layer (2) and the sealing layer (4).

Description

[0001] The invention relates to a method for producing a decorative element and to a decorative element, in particular produced by the method according to the invention.

[0002] The state of the art has provided a variety of methods for refining surfaces using decorative elements, for example, in vehicles such as cars or ships. These primarily include the use of colors, special surface textures, or shapes.

[0003] For example, patent application DE 10 2007 028 822 describes a method for decoratively coating a panel, in which a printed decorative paper is applied to a panel and, after being coated with a resin-containing coating, pressed onto it. According to patent application EP 1 649 999, a thin, dimensionally stable textile structure is formed from a textile fabric and a curable matrix material, which is back-injected with a curable molding compound in an injection molding process.

[0004] It's particularly popular to cover vehicle body panels with fabric mats, such as those made of carbon fiber, or to replace the body panels with replicas made of fabric mats. Due to their woven structure, carbon mats exhibit a three-dimensional appearance that, when exposed to light, creates aesthetically pleasing depth effects. This depth effect is further enhanced by the strong light-reflecting properties of the carbon fibers used in the carbon mats, creating a glossy effect.

[0005] Furthermore, decorative elements with three-dimensional patterns are known, which, for example, represent lettering or a company logo and, as part of the surface finishing, create particularly beautiful depth effects (3D effects) on the decorative elements when exposed to light.

[0006] However, the production of such decorative elements with a pattern presents the problem that the applied pattern is difficult to handle and position during production, and its position is difficult to fix. During the positioning and fixation of the pattern, changes in shape often occur, which must be avoided. These difficulties are particularly evident with pattern elements made of textile materials, such as textile fibers, threads, or yarns used in embroidery, for example.

[0007] Patent application US 2005 / 0164578 A1 describes a precursor for a composite material, said precursor comprising a layer of a structural fabric formed from reinforcing fibers, which has stabilizing fibers which dissolve at a dissolution temperature in a resin used in the production of the composite material.

[0008] From DE 10 2007 028 822 A1 a method for producing decorative coatings on carrier elements as well as a coated carrier element obtained by the method are known, wherein first a decorative paper is provided with a pattern, the decorative paper is placed on a carrier element and then sealed with an overlay paper or a liquid resin.

[0009] DE 10 2008 045 133 A1 discloses a decorative element comprising a carrier element, a sealing layer, a pattern and a transparent carrier layer, wherein the pattern is arranged between the carrier element and the sealing layer.

[0010] US 6 083 590 A discloses a decorative element comprising a carrier element, a sealing layer and an embroidery pattern in the form of an air embroidery arranged between the carrier element and the sealing layer.

[0011] US 2015 / 0047780 A1 describes a multi-layer structured textile, where fibers of one layer are dissolved in contact with injected resin.

[0012] EP 2 447 307 A2 discloses a composite material with a reinforcing fabric layer, the fibers of which are soluble in uncured epoxy resin with which the reinforcing fabric layer is impregnated.

[0013] DE 10 2005 034 401 A1 describes a process for producing fiber preforms using the TFP process, in which a support layer is formed from a dissolvable material that is removed or dissolved out during production.

[0014] It is therefore an object of the invention to provide a method for producing a novel decorative element which enables reliable production of the decorative element.

[0015] To achieve this object, the invention provides a method having the features of claim 1. The desired pattern is therefore not directly connected to the carrier element and processed, but first applied to a carrier layer. This solves the problem of the pattern slipping or becoming distorted during processing because the carrier layer prevents unwanted movement of the pattern. The fixation of the carrier layer together with the pattern as well as protection from the environment are achieved according to the invention by covering the carrier layer with a sealing layer. Since the carrier layer dissolves or becomes transparent upon contact with the sealing layer, the carrier layer does not have a negative effect on the visual appearance of the decorative element. It is preferably provided that the carrier layer is a textile.

[0016] The pattern is created by embroidery. Depending on the nature of the carrier element, applying the embroidery directly to the carrier element can be difficult or even impossible. If the carrier element is a flexible fabric, for example, it would become distorted due to the thread tension that occurs during the embroidery process. By applying the embroidery to a separate carrier layer, a carrier layer with sufficient rigidity or stability can be used. Because the carrier layer becomes invisible or dissolves during the further manufacturing process, a particularly appealing optical effect is achieved in that the embroidery appears to be floating on the carrier element. This creates a three-dimensional structure.

[0017] The vacuum-based resin injection process involves applying an air-permeable, but not material-permeable, membrane to the carrier element or carrier layer at a distance appropriate to the finished product. An air-impermeable barrier film is then applied to this membrane. A vacuum is then created within the cavity formed by the barrier film, so that the material to be applied, in particular the sealing layer material, is drawn in and evenly distributed between the carrier element or carrier layer and the membrane due to the vacuum. The air is drawn through the membrane and then transported away between the membrane and the barrier film.In contrast to other processes, this type of production avoids air pockets and other irregularities in the distribution of the sealing layer material, so that a uniform, homogeneous sealing layer can be created.

[0018] The dissolution or transparency of the carrier layer can be achieved in particular by making the carrier layer water-, resin-, lacquer-, or heat-soluble. This allows at least partial dissolution of the carrier layer upon contact with the material of the sealing layer, with any undissolved portion of the carrier layer becoming transparent during this process step or in a subsequent process step. If a heat-soluble carrier layer is used, it is preferably provided that it dissolves at temperatures of > 40°C, preferably > 90°C.

[0019] Embroidery is preferably carried out using a yarn made of heat-resistant material, such as polyester fibers, cotton or aramid fibers, so that it is not damaged by the application of the sealing layer or a subsequent heat treatment of the layer.

[0020] A particularly preferred embodiment provides for the sealing layer to be cured using a heat treatment. Resins such as epoxy resins, in particular, can be cured after application to achieve the optimal properties of these materials. Such a heat treatment can, for example, be a resting phase at or above room temperature or heating in an oven. Within the scope of this embodiment, it is further preferably provided that the carrier layer dissolves or becomes transparent during this heat treatment. This allows two manufacturing steps—namely, the curing of the sealing layer and the dissolution or transparency of the carrier layer—to be combined.

[0021] Furthermore, it is preferably provided that the carrier element is formed from a mat, for example, consisting of or comprising carbon or glass fibers, in particular from a carbon fiber or glass fiber fabric. Due to their stable properties, such mats can be used in many areas, for example, in vehicle construction. Furthermore, the optical properties of such mats when exposed to light, together with patterns, enable the production of a wide variety of decorative elements. Alternatively, the carrier element can also be a finished component, for example, made of metal or plastic, which is additionally decorated using the method according to the invention.

[0022] In a preferred embodiment, the carrier layer is at least partially dissolved during the provision of the carrier element with the sealing layer. This allows at least part of the carrier layer to be dissolved during the production of the sealing layer. Further treatment, e.g., using heat to dissolve the carrier layer or make it transparent, can therefore be completely eliminated or at least facilitated.

[0023] After the decorative element has been manufactured using the method according to the invention, it is typically cut to the required shape and further processed. Alternatively, the carrier element can also be applied to a finished component, so no further processing is necessary.

[0024] According to a further aspect, the invention relates to a decorative element having the features of claim 7.

[0025] Furthermore, it is preferably provided that the sealing layer is formed from a resin, preferably an epoxy resin. Resin, in particular epoxy resin, is ideally suited for decorative elements of the type according to the invention due to its resistance to mechanical influences and its high temperature resistance.

[0026] In a preferred embodiment, the carrier element is a mat, for example, consisting of or comprising carbon or glass fibers, in particular a carbon fiber or glass fiber fabric. Due to their stable properties, such mats can be used in many areas, for example, in vehicle construction. Furthermore, the optical properties of such mats, which become apparent particularly when exposed to light, together with patterns, enable the production of a wide variety of decorative elements.

[0027] Furthermore, it is preferably provided that a water- or resin-soluble protective film is arranged between the pattern or the carrier layer and the sealing layer.

[0028] According to a further aspect, the invention relates to a vehicle comprising at least one decorative element according to the invention. Decorative elements according to the invention are suitable for all types of vehicles, for example, motor vehicles, motorcycles, construction machinery, boats or yachts, or aircraft.

[0029] The invention will be explained in more detail below with reference to an embodiment shown in the drawing. Fig. 1 a schematically illustrated decorative element according to the invention in cross section, Fig. 2 a decorative element according to the invention during production and Fig. 3 a plan view of the Fig. 2 decorative element shown.

[0030] In Fig. 1 schematically shows a decorative element, wherein 1 denotes a carrier element, for example, a mat made of carbon fibers or glass fibers. On this layer is a carrier layer 2, which is provided with a pattern 3, for example, an embroidery pattern. The carrier layer 2 is, for example, a nonwoven made of cellulose. The carrier layer 2 does not have to extend over the entire surface of the carrier element 1, but can only cover a portion of the carrier element 1, as shown in Fig. 1. In the finished state of the decorative element, the carrier layer 2 may already be completely dissolved or, as shown here, transparent. A sealing layer 4 is arranged on the carrier element 1 or the carrier layer 2, which in particular covers the pattern 3. The sealing layer 4 can be formed, for example, from a resin, in particular an epoxy resin. The decorative element has already been cut into a finished element and therefore has defined edges.

[0031] In Fig. 2 shows a decorative element according to the invention during the manufacturing process according to the invention. The carrier element 1 lies on a table 5. The carrier layer 2 with the pattern 3 is already arranged on the carrier element 1. A water- or resin-soluble protective film 6 is arranged on the carrier layer 2 or the pattern 3 in order to stabilize the carrier layer 2 and prevent tearing. A membrane 7 is arranged above the protective film 6, which is permeable to air but not permeable to the material of the sealing layer 4. The distance of the membrane 7 from the carrier element 1 or the protective film 6 defines the layer thickness of the sealing layer 4 to be produced. An air-impermeable boundary film 8 is arranged above the membrane 7.

[0032] The sealing layer 4 is produced as follows. In the gap 9 between the boundary film 8 and the membrane 7, air is sucked out via an air line 10, creating a vacuum in the gap 9 or in the sealing space 11 between the protective film 6 and the membrane 7. At the same time, a material that will form the sealing layer 4 is fed to the sealing space 11 via a material line 12. The vacuum distributes the material evenly throughout the entire sealing space 11. Such a process is also known as a vacuum-based (resin) injection process. Once the sealing space 11 is filled with the material, the sealing layer 4 now formed in the sealing space 11 is cured or dried, if necessary, to obtain a solid sealing layer 4. During the introduction of the material into the sealing space 11, the protective film 6 and the carrier layer 4 partially dissolve or become transparent.Alternatively, it can also be provided that the protective film 6 and the carrier layer 4 only dissolve or become transparent during a subsequent step, for example during a heat treatment.

[0033] The decorative element is then cut to size and further processed, for example, applied to the product, such as a vehicle.

[0034] In Fig. 3 is the Fig. The arrangement shown in Figure 2 is shown in a top view, with the boundary foil 8 and the membrane 7 not shown for clarity. The air line 10 and the material line 12 are arranged on opposite sides of the table 5. However, they can also be arranged differently, for example, side by side.

Claims

[1] A method for producing a decorative element, wherein an embroidery pattern (3) is embroidered onto a carrier layer (2), the carrier layer (2) is then placed onto a carrier element (1), whereupon the carrier element (1) and the carrier layer (2) together with the pattern (3) are provided with a sealing layer (4), so that the carrier layer (2) is arranged between the carrier element (1) and the sealing layer (4), and the carrier layer (2) consists of a material which dissolves or becomes transparent in contact with the material of the sealing layer (4), wherein the carrier layer is brought into contact with the sealing layer so that the carrier layer dissolves or becomes transparent, wherein the carrier layer (2), in particular the nonwoven, comprises cellulose, viscose, synthetic fibers, thermoplastics, such as polyester, polyvinyl alcohol, polyolefins or polyamides or consists of one of these materials or mixtures thereof, and wherein the sealing layer (4) is formed by a liquid plastic, wherein the carrier layer (2) is pressed onto the carrier element (1) by means of a vacuum-based introduction method, which comprises placing a membrane (7) and a boundary film (8) arranged thereover on a side of the carrier element (1) carrying the carrier layer (2) and subsequently generating a vacuum between the boundary film (8) and the carrier element (1) or the carrier layer (2), and wherein a water- or resin-soluble protective film (6) is arranged between the carrier layer (2) and the sealing layer (4). [2] Method according to claim 1, characterized by that the carrier layer (2) is soluble in water, resin, varnish or heat. [3] Method according to claim 1 or 2, characterized by that the liquid plastic is formed from a resin, epoxy resin or varnish. [4] Method according to one of claims 1 to 3, characterized by that the sealing layer (4) is cured by means of a temperature treatment, wherein it is preferably provided that the carrier layer (2) dissolves or becomes transparent during this temperature treatment. [5] Method according to one of claims 1 to 4, characterized by that the carrier element (1) is formed from a mat, for example consisting of or comprising carbon or glass fibers, in particular from a carbon fiber or glass fiber fabric. [6] Method according to one of claims 1 to 5, characterized by that the carrier layer (2) dissolves at least partially during the provision of the carrier element (1) with the sealing layer (4). [7] Decorative element, produced by a method according to one of claims 1 to 6, comprising a carrier element (1), a sealing layer (4) and a pattern (3) and a transparent carrier layer (2), wherein the pattern (3) is arranged between the carrier element (1) and the sealing layer (4), characterized by that the pattern (3) is an embroidery pattern and that a water- or resin-soluble protective film (6) is arranged between the pattern (3) or the carrier layer (2) and the sealing layer (4). [8] Decorative element according to claim 7, characterized by that the sealing layer (4) is formed by a resin, preferably an epoxy resin. [9] Decorative element according to claim 7 or 8, characterized by that the carrier element (1) is a mat, for example consisting of or comprising carbon or glass fibers, in particular of a carbon fiber or glass fiber fabric. [10] Use of at least one decorative element according to one of claims 7 to 9 in a vehicle.

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