Design component for a vehicle

Abstract

The invention relates to a design component (10) for a vehicle (1), comprising a carrier housing (18) and a geometrically adapted film (12) flooded with a polyurethane layer (16) or a polyurea layer, which is connected to the carrier housing (18) via a frame (14) injection-molded onto an edge of the film (12), which has at least one fastening element (14.1), and a method for manufacturing such a design component (10).

Description

[0001] The invention relates to a design component for a vehicle. Furthermore, the invention relates to a corresponding method for producing such a design component.

[0002] Numerous variations of design components for vehicles and corresponding processes for manufacturing such design components are known. State-of-the-art design components, such as a backlit front panel for a vehicle front, are known, featuring an inserted and printed film, which are manufactured using a 3K injection molding process (3K: three components). The inserted film is first fully back-injected with a transparent polycarbonate as the first component. A surrounding frame with fastening elements is then injection-molded on as the second component. As the third component, the visible side of the printed film is flooded with polyurethane to protect the visible side of the component.

[0003] A disadvantage is that such large design components require correspondingly large injection molding machines, which have to be manufactured as custom-made products, as well as tools, which are very expensive.

[0004] DE 10 2006 046 436 B3 discloses a cover element for an opening in a vehicle, which comprises an at least partially metallized film. The film is overmolded on a front side with a layer of a first plastic and back-molded on a back side with a cover layer of a second plastic.

[0005] DE 10 2020 000 921 A1 discloses a method for producing a cladding element for a vehicle. In this method, at least one ornament with a three-dimensional appearance is applied to a transparent body having a visible side and an object side, and the object side is covered with a privacy screen. In this method, the privacy screen, consisting of an opaque lacquer, is applied over the entire surface of the object side of the transparent body, and the opaque lacquer covering the at least one ornament is subsequently burned out with a laser.

[0006] The invention is based on the object of providing a design component for a vehicle and a corresponding method for producing such a design component, which can be produced cost-effectively.

[0007] This object is achieved by a design component for a vehicle having the features of patent claim 1 and by a method for producing such a design component having the features of patent claim 6. Advantageous embodiments with expedient further developments of the invention are specified in the dependent patent claims.

[0008] In order to provide a design component for a vehicle which can be manufactured cost-effectively, the design component comprises a carrier housing and a film which is geometrically adapted thereto and flooded with a polyurethane layer or a polyurea layer and which is connected to the carrier housing via a frame which is injection-molded onto an edge of the film and which has at least one fastening element.

[0009] Furthermore, a method for producing such a design component is proposed, comprising the following steps: Providing a film. Injection-molding a frame with at least one fastening element onto an edge of the film. Flooding a visible side of the film with a polyurethane layer or a polyurea layer, and connecting the frame of the flooded film to a rear support housing via the at least one fastening element.

[0010] The term "foil" refers to a pretreated, preferably printed, foil. The foil can be hot-stamped and / or have a PVD coating. It is also possible to apply graphic objects to the surface of at least one of the two sides of the foil using other suitable methods. The foil can preferably have a thickness in the range of 0.5 to 4 millimeters.

[0011] Embodiments of the design component according to the invention for a vehicle can preferably be designed as a front panel for a vehicle front end and can advantageously be manufactured using a 2K injection molding process (2K: two components) with more cost-effective tools and a shorter manufacturing process. This allows the design components according to the invention to be manufactured more cost-effectively with the same appearance and performance. The frame can be continuous or intermittent. The frame can be made of a polycarbonate plastic (PS) or an acrylonitrile-butadiene-styrene copolymer plastic (ABS), or a mixture of the two plastics.

[0012] In an advantageous embodiment of the design component, at least one support element can be arranged on the carrier housing, which supports the flooded film on its rear side. This can increase the stability of the flooded film.

[0013] In a further advantageous embodiment of the design component, at least one light source can be arranged in the support housing to illuminate the flooded film from behind. This allows various optical effects to be created and implemented.

[0014] In an advantageous embodiment of the process, the molded-on frame can form a sealing edge for the flooding process. This can prevent the polyurethane from flowing into the cavity of the injection mold.

[0015] The features and feature combinations mentioned above in the description, as well as the features and feature combinations mentioned below in the description of the figures and / or shown alone in the figures, can be used not only in the respective combinations specified, but also in other combinations or on their own, without departing from the scope of the invention. Thus, embodiments are also to be considered encompassed and disclosed by the invention that are not explicitly shown or explained in the figures, but which emerge and can be produced from the explained embodiments through separate feature combinations.

[0016] Embodiments of the invention are illustrated in the drawings and explained in more detail in the following description. In the drawings, like reference numerals designate components or elements that perform the same or similar functions. Herein: Fig. 1 a schematic and partial representation of a vehicle with an embodiment of a design component according to the invention; Fig. 2 a schematic sectional view along the section line II - II in Fig. 1; and Fig. 3 a schematic flow diagram of an embodiment of a method according to the invention for producing a design component from Fig. 1 and Fig. 2.

[0017] As from Fig. 1 and Fig. 2, the illustrated embodiment of a design component 10 according to the invention for a vehicle 1 comprises a carrier housing 18 and a film 12 which is geometrically adapted thereto and flooded with a polyurethane layer 16 (PUR) or with a polyurea layer (PUA), which is connected to the carrier housing 18 via an injection-molded frame 14 with at least one fastening element 14.1.

[0018] In the illustrated embodiment, the design component 10 is designed as a backlit front panel for a front end 3 of the vehicle 1. The frame 14 is provided with a plurality of fastening elements 14.1 designed as receiving elements, which partially encompass an edge of the carrier housing 18. Furthermore, in the illustrated embodiment, the film 12 is printed on the surface of at least one of its two sides and flooded with a polyurethane layer 16 (PUR).

[0019] As from Fig. As can be further seen in Figure 2, two support elements 18.1 designed as partition walls are arranged on the carrier housing 18, which support the flooded film 12 at its rear. In the illustrated embodiment of the design component 10, three lamps 19 are arranged in the carrier housing 18 for rearwardly backlighting the flooded printed film 12. The lamps 19 are separated from one another by the support elements 18.1 designed as partition walls.

[0020] In the illustrated embodiment, the printed film 12 has a thickness ranging between 0.5 and 4 millimeters. The surrounding frame 14 consists of a mixture of a polycarbonate plastic (PS) and an acrylonitrile-butadiene-styrene copolymer plastic (ABS) in the illustrated embodiment. In alternative embodiments of the design component 10 (not shown), the frame 14 consists either of a polycarbonate plastic (PS) or of an acrylonitrile-butadiene-styrene copolymer plastic (ABS). Furthermore, the frame 14 can also be designed with interruptions.

[0021] As from Fig.As can be further seen in Figure 3, the illustrated embodiment of a method 100 according to the invention for producing a design component 10 comprises a step S100 in which a film 12 is provided. In a step S110, a frame 14 with at least one fastening element 14.1 is injection-molded onto an edge of the film 12. In a step S120, a visible side of the film 12 is flooded with a polyurethane layer 16 (PUR) or a polyurea layer (PUA). In a step S130, the frame 14 of the flooded film 12 is connected to a rear carrier housing 18 via the at least one fastening element 14.1.

[0022] The molded-on frame 14 forms a sealing edge for the flooding process. Furthermore, the support housing 18 comprises at least one support element 18.1, which supports the flooded film 12 on its rear side and increases the stability of the flooded film 12. LIST OF REFERENCE SYMBOLS 1 vehicle 3 Vehicle front 10 design components 12 slides 14 frames 14.1 Fastening element 16 Polyurethane layer (PUR layer) 18 carrier housings 18.1 Support element 19 light bulbs 100 processes for manufacturing a design component S100 to S130 process step QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2006 046 436 B3

[0004] DE 10 2020 000 921 A1

[0005]

Claims

[1] Design component (10) for a vehicle (1), comprising a carrier housing (18) and a film (12) geometrically adapted thereto and flooded with a polyurethane layer (16) or with a polyurea layer, which is connected to the carrier housing (18) via a frame (14) injection-molded onto an edge of the film (12) and having at least one fastening element (14.1). [2] Design component (10) according to claim 1, characterized by that the frame (14) is designed to be continuous or with interruptions. [3] Design component (10) according to claim 1 or 2, characterized by that at least one support element (18.1) is arranged on the carrier housing (18), which supports the flooded film (12) on its rear side. [4] Design component (10) according to one of claims 1 to 3, characterized by that at least one illuminant (19) for rear-illuminating the flooded film (12) is arranged in the carrier housing (18). [5] Design component (10) according to one of claims 1 to 4, characterized by that the film (12) has a thickness in the range between 0.5 and 4 millimeters. [6] Design component (10) according to one of claims 1 to 5, characterized by that the frame (14) consists of a polycarbonate plastic (PC) or of an acrylonitrile-butadiene-styrene copolymer plastic (ABS) or of a mixture of the two plastics. [7] Method (100) for producing a design component (10) according to one of claims 1 to 6, comprising the steps of: providing a film (12), injection-molding a frame (14) with at least one fastening element (14.1) onto an edge of the film (12), flooding a visible side of the printed film (12) with a polyurethane layer (16) or a polyurea layer, and connecting the frame (14) of the flooded film (12) via the at least one fastening element (14.1) to a rear carrier housing (18). [8] Method (100) according to claim 7, characterized by that the frame (14) is molded all around or with interruptions. [9] Method (100) according to claim 7 or 8, characterized by that the molded frame (14) forms a sealing edge for the flooding process. [10] Method (100) according to one of claims 7 to 9, characterized by that the carrier housing (18) comprises at least one support element (18.1) which supports the flooded film (12) on its rear side.

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