METHOD FOR INTEGRING A LIGHTING DEVICE INTO A SPACING LAYER

Abstract

A method for integrating a lighting device into a spacer layer for an interior component is proposed. The method comprises providing a spacer material configured to be installed as a spacer layer within the interior component, and cutting the spacer material to create at least one cut, the cut being configured to open an access point to an interior space within the spacer material. Furthermore, the method comprises providing a lighting device configured to be at least partially arranged and fixed within the interior space of the spacer material, and arranging at least a portion of the lighting device within the interior space of the spacer material using the at least one cut in the spacer material.

Description

Technical area

[0001] The present invention relates to a method for integrating a lighting device into a spacer layer for an interior component. Furthermore, the invention relates to a spacer layer with an integrated lighting device for an interior component, as well as to an interior component with a spacer layer. State of the art

[0002] According to the state of the art, lighting concepts for the backlighting of decorative elements for light decorations are usually based on backlighting via a dimensionally stable, transparent carrier layer for the decorative element, which can be made of polycarbonate, for example. However, backlighting via the carrier layer does not allow the use of more cost-effective, non-translucent standard carriers made of polypropylene fiberglass. Likewise, a carrier made of conventional polycarbonate cannot be used, as this does not meet crash safety requirements. Furthermore, stiffening ribs and mounting domes on a transparent polycarbonate carrier can negatively influence the resulting light pattern when backlit due to inhomogeneous light transmission.

[0003] The inventors of the present invention found that it would be advantageous to use an improved backlighting of decorative elements for light decorations, in which a transparent, dimensionally stable carrier can be dispensed with.

[0004] There is therefore a need for an improved method for integrating a lighting device into an interior component that enables uniform and efficient backlighting of decorative elements without relying on a transparent, dimensionally stable carrier. Description of the invention

[0005] An object of the invention is therefore to provide an improved method for integrating a lighting device into a backlit interior component, in which the use of a transparent, dimensionally stable carrier can be dispensed with and which allows efficient and space-saving backlighting of decorative elements.

[0006] The object is achieved by the subject matter of the independent claims. Advantageous developments of the invention are specified in the dependent claims, the description, and the accompanying figures.

[0007] The described embodiments apply equally to the method for integrating a lighting device into a spacer layer for an interior component, the spacer layer with an integrated lighting device for an interior component, and the interior component with a spacer layer. Synergistic effects can arise from various combinations of the embodiments, even if they are not described in detail.

[0008] Furthermore, it should be noted that all method-related embodiments of the present invention can be carried out in the described order of steps. Nevertheless, this need not be the only possible or required order of steps in the method. The methods described herein can be carried out in a different order of the disclosed steps without deviating from the corresponding method embodiment, unless expressly stated otherwise below.

[0009] According to a first aspect of the invention, a method for integrating a lighting device into a spacer layer for an interior component is proposed. The method comprises the step of providing a spacer material designed to be incorporated into the interior component as a spacer layer, and the step of cutting the spacer material to introduce at least one cut into the spacer material, wherein the cut is designed to open access to an interior space of the spacer material. Furthermore, the method comprises the step of providing a lighting device designed to be at least partially arranged and fixed in the interior space of the spacer material, and the step of arranging at least a portion of the lighting device in the interior space of the spacer material using the at least one cut in the spacer material.

[0010] According to the invention, functional openings are thus specifically introduced into a provided spacer material, into which a lighting device with or without additional electronics, such as sensors, is introduced, positioned and fixed.

[0011] The spacer material can be a blank that is already cut to the dimensions of the interior component to be covered. It is preferably a transparent or at least partially transparent spacer material, which may or may not be pre-coated. Pre-coating may be necessary to guarantee cutting accuracy with a flexible spacer material. Pre-coating, for example, a composite with at least a partial embedding of a cover layer of the spacer fabric, can also be used to create an improved version of a film hinge.

[0012] This spacer layer, which emits light due to a built-in lighting device, can preferably be used as a haptic layer in combination with a decorative layer and a dimensionally stable carrier layer. The spacer layer is located between the carrier layer and the decorative layer. The material used for the carrier layer can be, for example, polypropylene glass fiber PPGF, as used in interior components such as the center console, the instrument panel, or the door trim of a vehicle. The decorative material can be made of, for example, leather, artificial leather, film, textile, or wood, preferably flexible wood. The lighting device built into the spacer layer can also protrude from the spacer layer, so that, for example, a light source projects into a recess in the decorative element, as can be the case with three-dimensional backlit patterns of the decorative element.

[0013] The lighting device is preferably designed to be flexible, so that the lighting device can form a concealable, flexible unit with the spacer layer.

[0014] By integrating a lighting device into a spacer layer, such as a spacer fabric on a soft-laminated interior component, a transparent, dimensionally stable support is no longer required. Furthermore, the installation space can be significantly reduced, as the housing for a lighting device, previously attached to the back of the dimensionally stable support, can be omitted. Furthermore, the required amount of light can be reduced, as the light path and resulting negative light influences can be reduced due to the shorter and more direct light path.

[0015] In one embodiment of the invention, the spacer material is a knitted spacer fabric. Preferably, a transparent spacer material is used, and particularly preferably a textile, such as a knitted spacer fabric, in which two textile surfaces are kept apart by spacer-maintaining connecting threads, the pile threads. However, the spacer layer can also be a heating mat with heating wires, into which the lighting device is integrated, or a foam.

[0016] In one embodiment of the invention, the spacer material is cut by laser cutting. In this case, access and exit points for the lighting device can also be introduced into the spacer material by laser cutting. For example, tabs can also be cut into at least one cover layer of the spacer fabric in a meandering shape as a positioning and / or fixing aid for the insertion of the lighting device.

[0017] In one embodiment of the invention, cutting the spacer material comprises making a plurality of cuts in the spacer material, and / or cutting the spacer material creates a cavity in the interior of the spacer material. Preferably, the cutting is performed using multi-stage laser cutting, in which multiple cuts are made in the spacer material, which may have different depths, and / or are created using different laser trajectories or laser powers. The width of the cutting gap or the dimension of the hollow in the pile thread area of ​​the spacer fabric caused by combustion is influenced not only by the laser power and the laser speed, but also by, among other things, the type of textile construction, such as hollow area sizes, the use of multifilament or monofilament threads, or by the textile material itself.During cutting, the spacer material can be opened so that the lighting device can be inserted into the interior of the spacer material through a slit created by the cut. Alternatively, a portion of the spacer material can be cut out, which can then be reinserted into the spacer layer after the lighting device has been arranged in the interior of the spacer material. It is also possible to partially cut out a segment of the spacer material. This segment can remain hinged to the spacer material via a remaining piece of the residual wall thickness of a cover layer of a knitted spacer fabric used as the spacer material and can thus be folded out. After the segment of the spacer material has been folded out, it can optionally be hollowed out by making one or more cuts in its interior to create space for the lighting device.After arranging the lighting device in the interior of the segment, it can be folded back into the spacer layer and, for example, fixed flush in the spacer layer using an adhesive layer.

[0018] Laser trimming can, for example, be performed in two stages: in the first stage, a rectangular laser path is cut down to a residual wall thickness, and in the second stage, an interrupted linear laser path is cut continuously through the spacer material. The first stage can also be linear, down to a residual wall thickness, and the second stage can be a linear, interrupted cut continuous through the material. Alternatively, a single-stage trim can be performed on a residual wall thickness, for example, rectangular or linear.

[0019] In one embodiment of the invention, the lighting device essentially has an extension in one dimension, and the lighting device is arranged in a meandering shape in the interior of the spacer material, or the lighting device has a plurality of segments that are connected to one another by at least one material web. The lighting device can, for example, be linear, cord-like, thread-like, web-like, ribbon-like, or braid-like. For example, a coated light guide or an LED light strip can be used, which can have functional, positioning, or fixing properties. Thus, the lighting device can at least partially have soft or springy properties. In addition to the examples already mentioned, the lighting device can also be a matrix light with a dynamic light sequence.Different light strips from one or more lighting devices can also intersect, or the lighting device can have branches. The LED light strips can, for example, be connected to a control unit for a dynamic RGB lighting sequence. A lighting device can comprise a plurality of bundled light-conducting filaments, which are bundled, for example, into a round or flat cross-section. The diameter of the bundle can preferably be in the range of 0.5 to 3 mm.

[0020] In one embodiment of the invention, the lighting device has at least one fastening device designed to be fixed in the interior of the spacer material, and the fastening device is preferably a piping flag attached to the lighting device. The lighting device can be a light guide, which is, for example, covered with a piping flag, which can also be trimmed. Webs protruding from the lighting device can thus serve as a positioning aid and / or serve to fix the lighting device in the spacer material. These fastening devices, such as the protruding webs, preferably have soft, springy, or damping properties. Further examples of a fastening device are a transparent tube, a tube-like structure, a tube with a sheath and piping flag, or a housing. The piping flag can be post-processed.In the area of ​​the piping strip, the textile ends of a one-piece covering of the lighting device can be welded together, for example by ultrasonic welding. A web area of ​​the piping strip can be formed from a joined and a non-joined area, whereby the non-joined area can be folded apart to create two fastening webs. Multiple piping strips on one lighting device are also possible. Fastening devices can also be spacers, which can be part of the lighting device. The fastening device can, for example, be arranged and fixed within the spacer material, but can alternatively also protrude from the spacer layer. The piping webs can, for example, be flexible, deformed, or have curvatures.

[0021] In one embodiment of the invention, the method further comprises the step of at least partially closing the at least one cut in the spacer material after arranging the lighting device in the interior of the spacer material. Thus, the cut area can optionally be sealed and / or filled to prevent sagging or marking of the lighting device or the one or more cuts on the visible side of the decorative element. For example, an adhesive, polymer, adhesive tape, or spacer material can be used for this purpose.

[0022] In one embodiment of the invention, the method further comprises the step of applying a stiffening layer to at least one surface of the spacer material. This stiffening layer can be a film or an adhesive layer, which can prevent the lighting device incorporated into the spacer material or the at least one cut from being imprinted on the visible side of a decorative element applied to the spacer material.

[0023] According to a further aspect of the invention, a spacer layer with an integrated lighting device for an interior component is proposed, which is produced according to the method according to one of the preceding embodiments. Preferably, this is a transparent or at least partially transparent spacer material such as a knitted spacer fabric, which may or may not be pre-coated. The pre-coating can, for example, have stabilizing properties under stress, UV radiation, or with regard to thermal oxidation, and thus, for example, prevent yellowing. Together with a flexibly designed lighting device in the spacer layer, a concealable, flexible unit for backlighting a decoration for an interior component can be provided.

[0024] According to a further aspect of the invention, an interior component is proposed with a spacer layer according to one of the preceding embodiments, with a carrier layer to which the spacer layer is applied, and with a decorative layer applied to the spacer layer. This interior component has a carrier layer, for example made of polypropylene glass fiber PPGF or a natural fiber such as NFPP, onto which the spacer material with the integrated lighting device is laminated as a spacer layer or haptic layer. A decorative layer, which may be translucent or at least has openings filled with a translucent or transparent material, is located on the spacer layer. The decorative layer and the carrier layer can be adhesively bonded to the respective opposite sides of the spacer material.Optionally, a preferably transparent stiffening layer can be located between the decorative layer and the spacer layer, and / or a transparent stiffening layer can be applied to the side of the decorative layer facing the spacer layer.

[0025] By integrating a lighting device into a spacer layer, for example, preferably a spacer fabric on a soft-laminated interior component, the present invention eliminates the need for a transparent, dimensionally stable support. Likewise, the installation space can be significantly reduced, since, compared to previous concepts, the lighting device and its housing no longer need to be attached to the back of the dimensionally stable support. Furthermore, the required amount of light can be reduced, since the shorter light path and reduced negative influences on the transported light allow for more efficient use of the provided light.

[0026] A further advantage can be the cost-effective production of a backlit interior component, as well as homogeneous backlighting. Light scattering in a spot or cloud of light from the light source can also be significantly reduced, as there are fewer light-scattering layers above the lighting device. This is particularly advantageous when sharp light is required, for example, with a light spot that is intended to move dynamically along linear light openings in the decor. It also enables precise light introduction, as, for example, curved light lines in a decor do not require the use of large-area light guides or flat lighting devices.

[0027] Thus, the benefits offered by one of the above-mentioned aspects apply equally to all other aspects and vice versa.

[0028] Essentially, the invention relates to a method for integrating a lighting device into a spacer layer for an interior component. The method comprises providing a spacer material designed to be incorporated into the interior component as a spacer layer, and cutting the spacer material to introduce at least one cut into the spacer material, wherein the cut is designed to open access to an interior space of the spacer material. Furthermore, the method comprises providing a lighting device designed to be at least partially arranged and fixed in the interior space of the spacer material, and arranging at least a portion of the lighting device in the interior space of the spacer material using the at least one cut in the spacer material.

[0029] Further features, advantages and possible applications of the invention will become apparent from the following description of advantageous embodiments and the accompanying figures. Short character description

[0030] An advantageous embodiment of the invention is explained below with reference to the accompanying figures. Fig. 1 shows a block diagram of a method for integrating a lighting device into a spacer layer for an interior component according to an embodiment of the invention. Fig. 2 shows a schematic representation of an interior component with a spacer layer according to an embodiment of the invention. Fig. 3 shows a schematic representation of an interior component with a spacer layer according to a further embodiment of the invention. Fig. 4 shows schematic representations of a spacer layer with an integrated lighting device according to embodiments of the invention. Fig. 5 shows an interior component with backlit decorative elements according to an embodiment of the invention. Fig. 6 shows a schematic representation of a decorative layer with openings and an associated lighting device for integration into a spacer layer according to an embodiment of the invention. Fig. 7 shows a schematic representation of a decorative layer with openings for a backlit interior component with a spacer layer according to an embodiment of the invention. Fig. 8 shows schematic representations of a cross section of a lighting device with fastening devices for fastening the lighting device in a spacer material according to an embodiment of the invention.

[0031] The figures are merely schematic representations and serve only to illustrate the invention. Identical or equivalent elements are provided with the same reference numerals throughout. Detailed description

[0032] Fig. 1 shows a block diagram of a method for integrating a lighting device 125 into a spacer layer 120 for an interior component 100 according to one embodiment of the invention. The method comprises the step S110 of providing a spacer material designed to be incorporated into the interior component as a spacer layer, and the step S120 of cutting the spacer material to introduce at least one cut into the spacer material, wherein the cut is designed to open access to an interior space of the spacer material. Furthermore, the method comprises the step S130 of providing a lighting device designed to be at least partially arranged and fixed in the interior space of the spacer material, and the step S140 of arranging at least a portion of the lighting device in the interior space of the spacer material using the at least one cut in the spacer material.

[0033] Fig. 2 shows a schematic representation of an interior component 100 with a spacer layer 120 according to one embodiment of the invention. A spacer layer 120 made of a spacer material 121 is located between a carrier layer 110 and a decorative layer 130. The decorative layer, which can preferably be translucent, has openings 131 that can be filled, for example, with a transparent polymer. To backlight the decorative layer, a lighting device 125 is introduced into the spacer layer 120. For this purpose, the spacer material 121 is cut, preferably with a laser, and the resulting cut is used to introduce the lighting device 125 into the interior space 123 of the spacer layer 120. Optionally, the interior space 123 can be hollowed out before the lighting device 125 is introduced, for example, by burning out pile threads of a knitted spacer fabric used as the spacer material 121 by the laser.Alternatively, the interior of the spacer material 121, such as the pile threads, can be displaced and pushed aside during insertion of the lighting device 125. Optionally, the cut in the spacer material 121 created for inserting the lighting device 125 can be closed again, for example, by gluing or filling.

[0034] Fig. Figure 3 shows a schematic representation of an interior component 100 with a spacer layer 120 according to a further embodiment of the invention. Here, in addition to the Fig. 2, a stiffening layer 140 is provided between the spacer layer 120 and the decorative layer 130. This stiffening layer 140 can advantageously prevent the outlines of the lighting device 125 or the hollowing out of the spacer material 121 from being pressed through or marked by the at least one cut 122, and can thus ensure a flat surface of the decorative layer and thus of the interior component. Furthermore, in this embodiment, two adhesive layers 150 are shown, by means of which the spacer layer 120 can be bonded to the carrier layer 110 and the decorative layer 130 or the stiffening layer 140. In addition, the decorative layer 130 can be coated on the back, for example, with the same material with which the openings 131 are filled, which can contribute to the stiffening of the decorative layer 130, which in Fig. 3 but is not shown. The adhesive layers 150 and / or the stiffening layer 140 are preferably transparent, or at least partially translucent. The lighting device 125 is shown here with a curved or angled inlet or outlet, which is guided through the carrier layer 110. This preferably has a large radius of curvature. When passing through the carrier layer 110, a cannula or sleeve can be provided, which can contribute to strain relief in order to avoid tensile stress on the spacer material 121. This strain relief, in order to avoid deformation of the spacer fabric and surface collapse, can be supported, for example, by filling / stabilizing the area around the lighting device, such as hollow areas, with a preferably transparent polymer or spacer material. The filling / stabilization can take place after and / or before the integration of the lighting device 125.Optionally, a sleeve can be positioned and secured to protect the lighting device and prevent rubbing, creaking, bending, or damage. For the lighting device's exit, the exit area can be cut or cut out of the spacer material. At the end of the feed line 161 extending through the carrier layer 110, a coupling element 160 can be provided for coupling light into the light guide used here as the lighting device 125.

[0035] By incorporating rigid, transparent stiffening layers into the decoration, optionally also into a spacer material, for example, with a transparent dispersion or hotmelt, any pressure-through or marking on the visible decoration is avoided. The stiffening layer can also be bonded to the filling material or filling coating material of the decoration. Depending on the thickness of the stiffening layer, so that it is also suitable for lamination onto an inventive spacer material, it can be preheated sufficiently or more strongly on the side of the spacer material than with a decoration without a transparent stiffening layer or without a stiffening filling area. The use of relief aids between the lighting device 125 and the spacer material 121, such as ribbons, thread, adhesive tape, a cable guide or sleeve, or flexible bushings, for example made of rubber, or polymer fillings made of hotmelt or a dispersion, is advantageous.

[0036] Fig. Figure 4 shows schematic representations of a spacer layer 120 with an integrated lighting device 125 according to embodiments of the invention. Various cutting and incision combinations are shown, showing how different cuts 122 can be placed next to each other. This method allows for a wider laser gap or a hollowing out of the material. The cuts or lines can be created using different laser parameters. The spacer material 121 can be pre-coated before laser cutting for a defined burn-off. Fig. Figure 4A shows a hollowing out of the interior space 123 of the spacer layer 120 by burning out the pile thread. The cuts 122 can either pass through the entire spacer material 121, or a residual wall thickness can remain. Finally, the lighting device 125 is inserted into the interior space 123. Fig. 4B shows three cuts 122 made in the spacer material 121 at a small distance from each other. Material webs remaining between the cuts 122 can be displaced when the lighting device 125 is pressed into the interior space 123. Fig. 4C shows several cuts 122 that can be made in the spacer material 121 without any significant distance from each other, so that no material webs can remain.

[0037] Fig. 5 shows an interior component 100 with backlit decorative elements according to one embodiment of the invention. These are preferably three-dimensional light decorations. Transparent or translucent decorative materials, preferably flexible, pliable, or flexurally elastic materials, which have openings due to the materials used or the manufacturing processes used, can advantageously be used. Examples of decorative materials for illumination or backlighting are textiles, textile composites, films, printed films, and sintered or porous materials. Alternatively, openings for illumination or backlighting can be subsequently introduced into these by cutting, lasering, or punching. Openings for backlighting can be introduced into non-light-transparent decorative materials or decorative composites such as leather, synthetic leather, or textiles.Decorative materials incorporating 3D bodies or connecting areas such as transparent joints can be illuminated, transilluminated, or backlit using the inventive concept. For example, LEDs can be recessed or countersunk into the 3D bodies, allowing the spacer material and decorative layer to be opened up for the insertion or insertion of lighting devices such as LEDs. Electrical cables connecting the LEDs can also be positioned and fixed in the spacer layer using the inventive method.

[0038] Fig. Figure 6 shows a schematic representation of a decorative layer 130 with openings 131 and an associated lighting device 125 for integration into a spacer layer 120 according to an embodiment of the invention. Fig. 6A shows the decorative element with several slot-like openings 131, Fig. 6B Possibilities for designing a light guide, a light source, or a lighting device 125 on a spacer material 121. Several strands or segments 126 of a lighting device can be connected to one another via a connection, such as the material webs 127. These areas can be lasered free on the spacer material. This design of the lighting device 125 from interconnected segments avoids radii when laying in loops and leads to less distortion when mounting the lighting device 125 in a spacer material 121 and improved light transmission. For example, an LED can be attached to each light guide via a coupling element. Light strips can also be used.

[0039] Fig. Figure 7 shows a schematic representation of a decorative layer 130 with openings 131 for a backlit interior component 100 with a spacer layer 120 according to one embodiment of the invention. In this example, intersecting light lines or openings 131 are shown. Such geometries can also be advantageously backlit evenly and homogeneously with a spacer layer 120 with an integrated lighting device 125.

[0040] Fig. Figure 8 shows schematic representations of a cross-section of a lighting device 125 with fastening devices 128 for fastening the lighting device 125 in a spacer material 121 according to one embodiment of the invention. Several light guide threads, for example, with a diameter of 0.5 mm, can be arranged in a bundle and optionally provided with a transparent sheath, for example made of textile. This can result in a light piping, preferably with flexible piping webs. The piping webs as fastening device 128 can also be deformed and / or have curvatures.

[0041] Fig. 8 shows a lighting device 125 with a straight piping as a fastening device 128 at the top, while the illustration below shows a folded piping with two wings.

[0042] Although the invention has been illustrated and described in detail in the drawings and the foregoing description, these drawings and descriptions are to be considered as illustrative or exemplary in nature and not as restrictive. The invention is not limited to the disclosed embodiments. Other variations of the disclosed embodiments may be understood and practiced by those skilled in the art to practice the claimed invention, based on the drawings, the disclosure, and the dependent claims.

[0043] Additionally, it should be noted that "comprising" does not exclude other elements or steps, and "a" or "an" does not exclude a plurality. Furthermore, it should be noted that features or steps described with reference to one of the above embodiments may also be used in combination with other features or steps of other embodiments described above. Reference signs in the claims are not to be considered as limitations. LIST OF REFERENCE SYMBOLS 100 interior components 110 Carrier layer 120 spacer layer 121 spacer material 122 cut 123 Interior 125 lighting device 126 Segment of the lighting device 127 Material bridge 128 Fastening device 130 decorative layer 131 Opening 140 stiffening layer 150 adhesive layer 160 coupling element 161 Feed

Claims

[1] A method for integrating a lighting device (125) into a spacer layer (120) for an interior component (100), the method comprising the steps: Providing (S110) a spacer material (121) designed to be incorporated into the interior component (100) as a spacer layer (120); Cutting (S120) the spacer material (121) to make at least one cut (122) in the spacer material (121), wherein the cut (122) is designed to open access to an interior space (123) of the spacer material (121); Providing (S130) a lighting device (125) which is designed to be arranged and fixed at least partially in the interior space (123) of the spacer material (121); and Arranging (S140) at least a part of the lighting device (125) in the interior space (123) of the spacer material (121) using the at least one cut (122) of the spacer material (121). [2] The method of claim 1, wherein the spacer material (121) is a spacer fabric. [3] The method according to any one of the preceding claims, wherein the cutting of the spacer material (121) is carried out by laser cutting. [4] The method according to any one of the preceding claims, wherein cutting the spacer material (121) comprises adding a plurality of cuts (122) into the spacer material (121), and / or wherein cutting the spacer material (121) creates a cavity in the interior (123) of the spacer material (121). [5] The method according to any one of the preceding claims, wherein the lighting device (125) has a substantially one-dimensional extension, and wherein the lighting device (125) is arranged in a meandering shape in the interior (123) of the spacer material (121), or the lighting device (125) has a plurality of segments (126) which are interconnected by at least one material web (127). [6] The method according to one of the preceding claims, wherein the lighting device (125) has at least one fastening device (128) which is designed to be fixed in the interior space (123) of the spacer material (121), and wherein the fastening device (128) is preferably a piping flag attached to the lighting device (125). [7] The method according to any one of the preceding claims, further comprising the step of at least partially closing the at least one cut (122) of the spacer material (121) after arranging the lighting device (125) in the interior space (123) of the spacer material (121). [8] The method according to any one of the preceding claims, further comprising the step of applying a stiffening layer (140) to at least one surface of the spacer material (121). [9] A spacer layer (120) with an integrated lighting device (125) for an interior component (100), produced by the method according to one of claims 1 to 8. [10] An interior component (100) comprising a spacer layer (120) according to claim 9, a carrier layer (110) to which the spacer layer (120) is applied, and a decorative layer (130) which is applied to the spacer layer (120).

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