METHOD FOR PRODUCING A DECORATIVE PART

Abstract

Method for producing a decorative part (18) in which a decorative layer (2) is covered over its entire surface with a carrier film (6) on the visible side and then the decorative layer (2) is provided with openings (10), wherein the carrier film (6) is not cut through, the decorative layer (2) provided with openings (10) and the carrier film (6) is placed in an injection molding tool and plastic is introduced into the injection molding tool to form an injection-molded layer (16) that abuts the decorative layer (2), so that after injection molding parts of the decorative layer (2) and parts of the injection-molded layer (16) abut the carrier film (6).

Description

[0001] The present invention relates to a method for producing a decorative part which is used, for example, as a lining element, in particular in a motor vehicle.

[0002] The present invention relates in particular to a method for producing a decorative part which is provided with openings which are backlit when installed, so that the design formed by the openings can have a special effect.

[0003] A decorative part of the type mentioned above can, for example, be designed as a backlit door sill of a motor vehicle, with the openings forming, for example, letters that make up the name of the motor vehicle manufacturer or the corresponding model.

[0004] DE 10 2014 106 585 A1 discloses a multilayer body and a method for its production. The method involves providing a carrier provided with an LED and a decorative layer. The two layers are bonded together by injecting a plastic material into the space between these layers.

[0005] DE 10 2009 004 985 A1 discloses an interior trim part for a vehicle with a decorative layer which is covered on the visible side with a transparent coating and provided with openings which are backed by a transparent plastic which is provided in a light path of a lighting means which is connected to the backlit decorative part via a carrier layer provided on the back of the decorative layer.

[0006] JP S63-288 093 A discloses a film-like support structure onto which conductor tracks are applied by printing an electrically conductive coating. The prepared film is inserted into an injection mold so that the film is pressed against a wall bordering the mold cavity. The conductor tracks are overmolded with a plastic that bonds to the film.

[0007] DE 10 2012 024 056 A1 discloses a method for back-injection molding a film layer whose visible side is placed against a fixed mold half of an injection mold. For this purpose, the film layer has an opening that is aligned with the sprue of the fixed mold half. Thus, the liquid plastic is forced through the film layer and against the back of the film layer, solidifying and bonding it.

[0008] Further decorative parts and methods for their production are disclosed in WO 00 / 46045 A3, DE 43 01 444 A1, DE 10 2010 017 494 A1, DE 10 2016 120 421 A1 and DE 10 2007 054 348 A1.

[0009] The present invention is based on the problem of providing a method for producing a decorative part with increased design variety.

[0010] To solve this problem, the present invention provides a method having the features of claim 1.

[0011] In this process, a decorative layer is provided with an injection-molded layer in a manner known per se in order to stiffen the decorative layer, which is initially not dimensionally stable on its own. The decorative layer can also be an initially planar, three-dimensionally formed decorative layer whose topography is fixed by the injection-molded layer. The injection-molded layer usually lies completely in contact with the decorative layer. In the claimed process, the injection-molded layer is preferably made of a transparent, for example a colored transparent or clear transparent plastic. According to the invention, the injection-molded layer lies against the decorative layer on the side opposite the carrier film. The carrier film is a film which, during the production of the openings, for example, holds and fixes surface sections of the decorative part that are completely removed from the material of the decorative part.The carrier film is therefore provided with an adhesive layer on the side adjacent to the decorative layer. This adhesive layer can be applied to the decorative layer beforehand. However, the adhesive layer can also be applied before the carrier film is applied, on the contact surface of the film that will be placed against the decorative layer.

[0012] The perforations are created after the carrier film has been applied. When creating the perforations, the carrier film is not severed, so that all surface areas of the decorative layer remain in place even after the perforations have been created. The perforations are preferably created using a process in which the material of the decorative layer removed in the perforations is removed without residue by the process itself. For example, the perforations are preferably lasered. This process vaporizes the material of the decorative layer without leaving any residue.

[0013] Textile material, a decorative film, a wood veneer or woven carbon fiber can be used as a decorative layer.

[0014] The process for forming the sprayed layer can be carried out, for example, in accordance with DE 43 01 444 A1 or DE 10 2012 014 028 A1.

[0015] DE 10 2015 005 591 A1 discloses a method for producing a decorative part, in which a decorative layer is provided with a carrier film. The carrier film and the decorative layer are provided with an opening that penetrates the decorative layer and extends into a carrier layer formed by the carrier film. The decorative part is dimensionally stable through back-injection on the rear side, enclosing the film. It can be over-injected on the visible side. The finished decorative part necessarily has the carrier layer between the decorative layer and the rear over-injection. In the present invention, the injected layer is injection-molded so as to lie against the decorative layer, while the opposite side of the decorative layer is only covered with the carrier film. Accordingly, in the process according to the invention, the decorative layer is reinforced by the injected layer on the side of the decorative layer opposite the carrier film.In the decorative part produced with the present invention, either the carrier film forms the outer surface of the decorative part or is removed from the decorative layer so that it either forms the visible side of the decorative part in an unsealed manner or is provided with a visible-side coating.

[0016] The injection-molded layer is preferably made of a transparent plastic, such as PMMA. The carrier film can still be provided on the finished lining part. In this case, the carrier film protects the decorative layer, for example on the visible side. The carrier film can have special properties for this purpose, such as being UV-resistant or absorbing or reflecting ultraviolet light in whole or in part, so that the decorative layer is less susceptible to aging or yellowing. During injection molding, the injection-molded layer is forced through the openings on the side opposite the carrier film until it reaches the carrier film. In this way, parts of the decorative layer and parts of the injection-molded layer rest against the carrier film.

[0017] Alternatively, the carrier film can also be removed after the injection-molded layer has been formed. In this preferred embodiment, the surface of the decorative layer and, if applicable, the plastic material located in the openings form the surface of the lining part. The decorative part is backlit in the installed position. For this purpose, the decorative part can be applied to a lighting device that is as flat as possible, which can, for example, be pre-mounted on a motor vehicle. Alternatively, the light source can also be provided directly on the decorative part, as can be seen from DE 20 2015 106 328 U1. In the present invention, a light source can also be mounted on the injection-molded layer or integrated into the injection-molded layer.Light guide paths can also be formed between the sprayed layer and the light source or within the sprayed layer in order to guide the light emitted by the light source to predetermined areas below the decorative layer or to focus it on these areas.

[0018] The decorative layer typically appears as a continuous layer with only the cutouts. These cutouts can form a design, lettering, and / or a logo.

[0019] In an alternative embodiment, in which the visible surface of the decorative layer is also sealed to protect against environmental influences, the carrier film is removed after the injection-molded layer has been formed and the decorative layer is provided with a visible coating on the side opposite the injection-molded layer. This visible coating can be a layer of paint or a film, whereby the film is a different film than the carrier film. In this case, too, the film can be glued to the decorative layer. The visible coating is preferably formed by a second injection-molded layer, which is usually also made of a transparent, possibly transparently colored plastic.This process offers the possibility of providing the decorative layer with a three-dimensional shape before forming the injected layer, which is secured by the first injected layer and sealed on the opposite side by the second injected layer.

[0020] Further details and advantages of the present invention will become apparent from the following description of an embodiment in conjunction with the drawing, which illustrates schematic sectional views of a decorative layer in various phases of the process.

[0021] In Fig. Figure 1 shows a sectional view of a decorative layer 2, to whose visible side 4 a carrier film 6 is applied. An adhesive film 8, located between the decorative layer 2 and the carrier film 6, acts as a bonding agent. This adhesive film 8 reversibly adheres the carrier film 6 to the visible side 4 of the decorative layer 2.

[0022] In Fig. Figure 2 shows the result of processing the decorative layer 2. The decorative layer 2 was provided with various perforations 10 using a laser, which are introduced into the decorative layer 2 at right angles from a rear side 12 of the latter. The perforations 10 extend completely through the decorative layer 2. They can partially extend into the adhesive film and, if necessary, even partially into the material of the carrier film 6. Typically, however, the decorative layer is processed using the kiss-cut process. This process typically does not result in any damage to the carrier film 6, so it can be removed without leaving any residue.

[0023] In the example after Fig. 2, the openings 10 are formed contiguously and form the letter O in plan view. This results in a surface section 14 in the middle that is not contiguous with the remaining part of the decorative layer 2.

[0024] This description also makes it clear that the patent description refers to multiple perforations to express that different surface areas of the decorative layer 2 are provided with such an opening 10. However, perforations within the meaning of the invention also exist when multiple recesses are provided in the decorative layer 2 that communicate with each other.

[0025] In Fig. 3, a carrier in the form of an injection-molded layer 16 is formed against the back 12 of the decorative layer 2. This injection-molded layer 16 lies flat against the back 12 of the decorative layer 2. During injection molding of the plastic forming the injection-molded layer 16, it also flows into the openings 10 up to the adhesive film 8. This results in the removal of the carrier film 6 (cf. Fig. 4) a smooth surface on the visible side 4 of the decorative layer 2, which is predominantly formed by the material of the decorative layer 2 and to a small extent by the plastic material forming the injection-molded layer 16.

[0026] The injected layer 16 is transparent, so that a light source provided on the back of the injected layer 16 or a light source introduced into the injected layer 16 optically highlights the openings 10, especially in the dark. Fig. As illustrated in Figure 4, the carrier film 6 is removed together with the adhesive film 8 without leaving any residue. Any remaining adhesive residue on the visible side 4 of the decorative part 18 formed by the decorative layer 2 and the injection-molded layer 16 is removed. This decorative part 18 can be used as an open-pore lining part. Alternatively, a second injection-molded layer can also be provided on the visible side 4 to seal the decorative layer 2. List of reference symbols 2 decorative layers 4 Visible side 6 Carrier film 8 adhesive tape 10 Breakthrough 12 Back 14 Area section 16 sprayed layers 18 decorative part

Claims

[1] Method for producing a decorative part (18), in which a decorative layer (2) is bonded to a carrier film (6) on the visible side and the decorative layer (2) is then provided with openings (10), wherein the carrier film (6) is not severed, the decorative layer (2) provided with openings (10) and the carrier film (6) is placed in an injection mold and plastic is introduced into the injection mold to form an injection-molded layer (16) lying against the decorative layer (2), so that after injection molding, parts of the decorative layer (2) and parts of the injection-molded layer (16) lie against the carrier film (6). [2] Method according to claim 1, characterized by that the injection-molded layer (16) is formed from a transparent plastic. [3] Method according to claim 1 or 2, characterized bythat the carrier film (6) is removed after the formation of the injection-molded layer (16) and the decorative part (18) is connected to a light source which backlights the decorative part (18). [4] Method according to one of the preceding claims, characterized by that the carrier film (6) is removed after the formation of the injected layer (16) and a visible coating is formed on the side (4) of the decorative layer (2) opposite the injected layer (16). [5] Method according to claim 4, characterized by that the carrier film (6) is removed after the formation of the injected layer (16) and a second injected layer is formed on the side (12) of the decorative layer (2) opposite the injected layer (16). [6] Method according to one of the preceding claims, characterized by that the openings (10) are formed up to or into the carrier film (6) without the carrier film (6) being pierced.

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