Decorative trim and manufacturing process for this

Abstract

A decorative aperture comprises a transparent resin layer, a translucent substrate designed to be arranged on a rear side of the transparent resin layer and designed to visually express a three-dimensional pattern created by an uneven surface of the translucent substrate, and a semi-translucent layer designed to be arranged on a rear side of the translucent substrate and to have a contour corresponding to the uneven surface of the translucent substrate.

Description

TECHNICAL AREA

[0001] The present invention relates to a decorative aperture and a manufacturing method for it. TECHNICAL BACKGROUND

[0002] Patent specification 1 cited below discloses a decorative film comprising a decorative layer and a light-shielding layer, which is capable of displaying an optical image of a predetermined shape on a surface by partially causing light emitted by an LED to pass through the light-shielding layer.

[0003] Patent specification 1 discloses a technique in which the decorative film is provided with an intermediate color layer arranged between the decorative layer and the light-shielding layer, such that the outline of the transparent section of the light-shielding layer lying below the intermediate color layer is inconspicuous when no optical image is displayed.

[0004] Patent specification 2 cited below discloses a decorative film in which light-reflecting protruding sections are formed on a sheet- or plate-like translucent substrate, thereby achieving a unique design for the light-reflecting protruding sections. RELATED DOCUMENTS PATENT DOCUMENT Patent document 1: Japanese patent no. 6899969 Patent document 2: Japanese patent no. 6405004 SUMMARY OF THE INVENTION PROBLEMS TO BE SOLVED BY THE INVENTION

[0005] However, as in Fig. As shown in Figure 4, uneven illumination of the optical image can occur when the decorative film from patent document 2 is provided with a semi-transparent layer and configured such that an optical image is visible from the front surface when the rear surface is illuminated, and an outer frame of the optical image is not visible from the front surface when the rear surface is not illuminated. This is because the thickness of the semi-transparent layer differs between the region with the light-reflecting protrusions and the region without them. DEVICE FOR SOLVING THE PROBLEM

[0006] A decorative panel, or decorative panel, according to one embodiment comprises a transparent resin layer, a translucent substrate configured to be arranged on a back side of the transparent resin layer and to visually express a three-dimensional pattern created by an uneven surface of the translucent substrate, and a semi-transmissive layer configured to be arranged on a back side of the translucent substrate and having a contour corresponding to the uneven surface of the translucent substrate. EFFECTS OF THE INVENTION

[0007] According to one embodiment of a decorative cover, a three-dimensional pattern is visible from the front surface, or end face, and uneven illumination of a graphic symbol can be suppressed. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 is a diagram that schematically illustrates a laminate structure of a decorative panel according to an exemplary embodiment. Fig. 2A is a top view of the in Fig. 1 decorative panel shown. Fig. 2B is a top view of the in Fig. 1 decorative panel shown. Fig. Figure 3 is a flowchart showing an example of a process flow for manufacturing the decorative panel according to the embodiment. Fig. Figure 4 is a diagram that schematically represents a laminate structure of a conventional decorative panel. Fig. 5A is a diagram showing an example of a three-dimensional pattern and graphic symbol on conventional decorative film or foil. Fig. 5B is a diagram showing an example of a three-dimensional pattern and graphic symbol on conventional decorative film. Fig. Figure 6A is a diagram showing an example of a three-dimensional pattern and graphic symbol on the decorative panel according to the embodiment. Fig. Figure 6B is a diagram showing an example of a three-dimensional pattern and graphic symbol on the decorative panel according to the embodiment. DESCRIPTION OF THE EXAMPLES OF EXECUTION

[0008] The following describes an exemplary embodiment with reference to the drawings. (Construction of the decorative aperture 100)

[0009] Fig. Figure 1 is a diagram that schematically illustrates a laminate structure of a decorative panel or decorative panel 100 according to the embodiment. Fig. 2 is a top view of the in Fig. 1 decorative aperture shown 100.

[0010] The in Fig. The decorative panel 100 shown is a plate-shaped component with a decorative pattern (e.g., grain, metal pattern, leather pattern, etc.) on a smooth front surface. When the decorative panel 100 is installed in any chosen location (e.g., in the interior of a motor vehicle), a decorative flat surface can be created at the installation point.

[0011] As in Fig. As shown in Figure 1, the decorative aperture 100 comprises a transparent resin layer 101, a binder layer 102, a translucent substrate 103, a semi-transmissive layer 104, a light-shielding layer 105 and a light source 106 in this order as seen from the front (top side in the drawing).

[0012] The transparent resin layer 101 is applied to the front surface of the binder layer 102. The transparent resin layer 101 is a transparent resin element in the form of a flat plate and is arranged as the outermost layer, forming the front surface of the decorative panel 100. The front surface of the transparent resin layer 101 is smooth. The rear surface, or back surface, of the transparent resin layer 101 has a contour corresponding to an uneven surface of the translucent substrate 103. For example, the transparent resin layer 101 is formed to have a smooth front surface and an uneven rear surface by coating the front surface of the binder layer 102, which has a contour corresponding to the uneven surface of the translucent substrate 103, with a flowable resin (e.g., injection molding resins).liquid injection molding (LIM), molten resins and the like) by overmolding, or insert molding using a transparent resin material.

[0013] The binder layer 102 is arranged on the front surface of the translucent substrate 103, in other words, between the translucent substrate 103 and the transparent resin layer 101. The binder layer 102 has a contour that corresponds to the uneven surface of the translucent substrate 103. The binder layer 102 is translucent. The binder layer 102 can also be light-diffusing. If the binder layer 102 is light-diffusing, the light entering from the front of the decorative aperture 100 is distributed, or scattered, such that the light is reflected over a wide area of ​​the translucent substrate 103, thereby improving the visibility of a three-dimensional pattern 103A created by the uneven surface of the translucent substrate 103.For example, the binder layer 102 is formed by printing translucent ink, or ink that has both translucent and light-diffusing properties, onto the front surface of the translucent substrate 103. The binder layer 102 is formed to have a contour corresponding to the uneven surface of the translucent substrate 103 by forming it integrally with the translucent substrate 103 by compression molding or hot pressing, or by an insert molding die to form the transparent resin layer 101.

[0014] The translucent substrate 103 is a sheet-shaped or foil-shaped element made of a translucent resin. The translucent substrate 103 has an uneven surface that creates the three-dimensional pattern 103A. The three-dimensional pattern 103A can, for example, represent the unevenness of a grain pattern or a metal pattern. Thus, the three-dimensional pattern 103A created by the uneven surface of the translucent substrate 103 is visible from the front surface of the decorative aperture 100 through the binder layer 102 and the transparent resin layer 101. In particular, because the translucent substrate 103 has an uneven surface, a three-dimensional pattern section 103B, which varies in height (i.e., depth) in the uneven surface, is visible from the front surface of the decorative aperture 100 as the contour line of the three-dimensional pattern 103A.For example, the translucent substrate 103 is produced by subjecting a film-shaped resin material with light transmissivity to thermal forming, such as three-dimensional overlay molding (TOM), or vacuum forming, thereby creating the uneven surface that generates the three-dimensional pattern 103A. In other words, unlike decorative patterns formed by conventional planographic printing, the decorative pattern of the three-dimensional pattern 103A in the present embodiment is perceptible in three dimensions when viewed from the front of the decorative aperture 100. This is due to the combined effects of decorative reflection.This is due to decorative reflection and shape-based reflection, which are generated by the three-dimensional pattern section 103B, which has a three-dimensionally uneven surface.

[0015] The semi-transparent layer 104 is applied to the rear surface of the transparent substrate 103. In particular, the semi-transparent layer 104 is designed to exhibit uniform transmission and a uniform film thickness across the entire rear surface of the transparent substrate 103. The semi-transparent layer 104 has a semi-transmissivity. Thus, the semi-transparent layer 104 prevents the transparent substrate from passing through.The light-transmitting section 105A of the light-shielding layer 105 is visible from the front of the decorative aperture 100 when no light is emitted from the light source 106, which is located on the back of the light-shielding layer 105, and allows the light passing through the transparent section 105A of the light-shielding layer 105, namely a graphic symbol 100A, to be visible from the front of the decorative aperture 100 when light is emitted from the light source 106, which is located on the back of the light-shielding layer 105. For example, the semi-transparent layer 104 is formed by printing smoke ink with semi-transparent properties onto the back surface of the transparent substrate 103.The semi-transparent layer 104 is formed integrally with the translucent substrate 103 by thermal or compression molding to have a contour that corresponds to the uneven surface of the translucent substrate 103.

[0016] The light-blocking layer 105 is arranged on the back surface of the semi-transparent layer 104. In other words, the light-blocking layer 105 is arranged as the outermost layer, forming the back surface of the decorative aperture 100. For example, the light-blocking layer 105 is formed by printing a light-blocking black ink onto the back surface of the semi-transparent layer 104. The light-blocking layer 105, together with the transparent substrate 103 and the semi-transparent layer 104, is thermoformed or compressed to obtain a contour that corresponds to the uneven surface of the transparent substrate 103.The light-shielding layer 105 blocks light from the back of the light-shielding layer 105, making various components (not shown) located on the back of the decorative panel 100 less visible when the decorative panel 100 is viewed from the front surface. The light-shielding layer 105 has a transmissive portion 105A along the outer frame of the graphic symbol 100A. Thus, the light-shielding layer 105 allows the graphic symbol 100A to be visible from the front of the decorative panel 100 when the back of the decorative panel 100 is illuminated with light.

[0017] The light source 106 is positioned on the back side of the light-shielding layer 105 at a predetermined distance from the light-shielding layer 105. The light source 106 can emit light towards the rear surface of the light-shielding layer 105. For example, an LED is used as the light source 106.

[0018] In the decorative aperture 100 configured as described above, as in Fig. Figure 2A shows that when no light is emitted from the light source 106 located on the back of the light-shielding layer 105, the light incident from the front of the decorative aperture 100 is reflected at the front surface of the translucent substrate 103, so that the three-dimensional pattern 103A, which utilizes the height difference of the translucent substrate 103, is visible from the front of the decorative aperture 100. At this time, the semi-transparent layer 104 of the decorative aperture 100 makes the outer shape of the transparent section 105A of the light-shielding layer 105 invisible from the front of the decorative aperture 100.

[0019] On the other hand, the light passes through, as in Fig. 2B shown, in the decorative aperture 100, when light is emitted from the light source 106 arranged on the back of the light-shielding layer 105, the transparent section 105A of the light-shielding layer 105, the semi-transparent layer 104, the translucent substrate 103, the binder layer 102 and the transparent resin layer 101, and is emitted from the front surface of the transparent resin layer 101, making the graphic symbol 100A formed by the transmitted light visible from the front surface of the decorative aperture 100.

[0020] In the decorative aperture 100 according to the embodiment, the semi-transparent layer 104 has a contour that corresponds to the uneven surface of the translucent substrate 103.

[0021] Thus, in the decorative aperture 100 according to the exemplary embodiment, the three-dimensional pattern 103A is visible from the front of the decorative aperture 100 due to the uneven surface of the translucent substrate 103. At the same time, the use of the semi-transparent layer 104 with a uniform film thickness effectively suppresses uneven illumination of the graphic symbol 100A, which would otherwise be caused by fluctuations or variations in the film thickness of the semi-transparent layer 104.

[0022] The decorative aperture 100 according to the embodiment is provided with the light-shielding layer 105, which is arranged on the rear surface of the semi-transparent layer 104, has a contour corresponding to the uneven surface of the translucent substrate 103, and has the translucent section 105A along the outer frame of the graphic symbol 100A.

[0023] By illuminating the back of the decorative aperture 100 according to the embodiment with light and allowing the light to pass through the decorative aperture 100, the graphic symbol 100A, whose uneven illumination is suppressed, can thus be displayed on the front surface of the decorative aperture 100.

[0024] The decorative aperture 100 according to the embodiment is provided with the light source 106, which is arranged on the back of the light-shielding layer 105, and when the light emitted by the light source 106 passes through the transparent section 105A of the light-shielding layer 105, the semi-transparent layer 104 and the translucent substrate 103, the graphic symbol 100A is displayed on the front surface of the transparent resin layer 101, which serves as the outermost layer of the decorative aperture 100.

[0025] Thus, according to the embodiment, the decorative aperture 100 can switch between displaying and not displaying the graphic symbol 100A by switching the light source 106 on or off, suppressing uneven illumination on the front surface of the transparent resin layer 101 while the three-dimensional pattern 103A remains visible.

[0026] In the decorative aperture 100 according to the embodiment, the semi-transparent layer 104 has a uniform light transmission and a uniform film thickness and is applied to the rear surface of the translucent substrate 103.

[0027] Thus, according to the embodiment, the decorative aperture 100 can suppress uneven illumination of the graphic symbol 100A due to uneven light transmission or film thickness of the semi-transparent layer 104.

[0028] (Example of a process for manufacturing the decorative aperture 100) Fig. Figure 3 is a flowchart illustrating an example of a method for manufacturing the decorative aperture 100 according to the embodiment.

[0029] First, the semi-transparent layer 104 with uniform light transmission and film thickness is formed by applying a semi-transparent smoke ink to the rear surface of the translucent substrate 103 using screen printing (step S301, step to form the semi-transparent layer).

[0030] Next, the light-shielding layer 105 is formed with a uniform film thickness by screen-printing a light-shielding black ink onto the back surface of the semi-transparent layer 104 formed in step S301 (step S301, step to form the light-shielding layer).

[0031] Next, the binder layer 102 is formed with a uniform film thickness by screen printing a translucent and light-scattering ink onto the front surface of the translucent substrate 103 (step S303, step to form the binder layer).

[0032] Next, an uneven surface corresponding to the three-dimensional pattern 103A is provisionally formed on the translucent substrate 103, on which the semi-transparent layer 104, the light-shielding layer 105, and the bonding layer 102 are formed, by pneumatic or thermal forming (step S304, step for provisional formation of the uneven surface). The provisional step for forming the uneven surface in step S304 can be omitted.

[0033] Next, the translucent substrate 103, on which the uneven surface was formed in step S304, is cut into an outer shape or form with a predetermined size by a press machine or a laser (step S305, step for cutting the outlines).

[0034] Next, the transparent resin layer 101 is formed by overmolding onto the front surface of the translucent substrate 103, the outer shape of which was cut in step S305, and an uneven surface corresponding to the three-dimensional pattern 103A is formed on the translucent substrate 103 (step S306, the overmolding step). Specifically, the translucent substrate 103 is placed in a mold and molten resin is poured into the mold to form the transparent resin layer 101 on the front surface of the translucent substrate 103.

[0035] In the method for producing the decorative aperture 100 according to the exemplary embodiment, the decorative aperture 100 comprises the transparent resin layer 101, the translucent substrate 103, which is arranged on the back of the transparent resin layer 101 and expresses a three-dimensional pattern through the uneven surface of the translucent substrate 103, and the semi-translucent layer 104, which is arranged on the back of the translucent substrate 103 and has a contour that corresponds to the uneven surface of the translucent substrate 103, and can be produced by the above method.

[0036] Thus, the decorative aperture 100 according to the exemplary embodiment can be produced using the method for manufacturing the decorative aperture 100 according to the exemplary embodiment, in which the three-dimensional pattern 103A is visible from the front and the uneven illumination of the graphic symbol 100A can be suppressed.

[0037] In the manufacturing process described above, a transparent layer can be formed between the semi-transparent layer 104 and the light-shielding layer 105 (step to form the transparent layer). In the laser processing described later, this transparent layer protects the semi-transparent layer 104 from the influence of a laser, and only the light-shielding layer 105 can be removed.

[0038] In the manufacturing process described above, the graphic symbol 100A is formed, for example, by forming the transparent section 105A along the outer frame of the graphic symbol 100A on the light-shielding layer 105 by laser processing, for example with an IR laser (step to form the graphic symbol).

[0039] In the case of the decorative aperture 100 produced according to the manufacturing process described above, if an unevenness of illumination is visually perceived, the unevenness of illumination can be eliminated by forming tiny coating film removal sections with a diameter of 25 µm or the like on the semi-transparent layer 104 by laser processing, for example with an IR laser (step to eliminate the unevenness of illumination). <vergleichsbeispiel>

[0040] The following is a comparative example of the decorative aperture 100 according to the exemplary embodiment, with reference to the Fig. 4, Fig. 5 to Fig. 6.

[0041] (Construction of a conventional decorative aperture 10) Fig. Figure 4 is a diagram that schematically illustrates the laminate structure of a conventional decorative panel 10. As shown in Fig. As shown in Figure 4, the conventional decorative film, or decorative film 10, comprises, in this order from the front (top side in the drawing), a translucent substrate 11, light-reflecting projection portions 12, a semi-transmissive layer 13, and a light-shielding layer 14.

[0042] As in Fig. As shown in Figure 4, the conventional decorative film 10 comprises the light-reflecting protruding sections 12, corresponding to a three-dimensional pattern, on the rear surface of the translucent substrate 11, so that a three-dimensional pattern 12A is visible from the front of the decorative film 10.

[0043] However, in the conventional decorative film 10, the thickness of the semi-transparent layer 13 differs between the region with the light-reflecting protrusions 12 and the region without the light-reflecting protrusions 12.

[0044] Therefore, in the case of the conventional decorative film 10, if both the region with the light-reflecting protruding sections 12 and the region without the light-reflecting protruding sections 12 are included in the region that overlaps a translucent or translucent section 14A of the light-shielding layer 14, as in Fig. As shown in Figure 4, uneven illumination of a graphic symbol 10A can occur when the back of the decorative film 10 is irradiated, because the thickness of the semi-transparent layer 13 varies.

[0045] (Display example for the three-dimensional pattern 12A and the graphic symbol 10A on the conventional decorative film 10) Fig. Figure 5 is a view showing a display example of the three-dimensional pattern 12A and the graphic symbol 10A on the conventional decorative film 10.

[0046] As in Fig. As shown in Figure 5A, the three-dimensional pattern 12A of the conventional decorative film 10 is visible from the front of the decorative film 10 when the back of the decorative film 10 is not illuminated by light. Because the conventional decorative film 10 has the semi-transparent layer 13, the transparent section 14A of the light-shielding layer 14 is less visible from the front of the decorative film 10 at this time.

[0047] Furthermore, as in Fig. 5B shows that, with the conventional decorative film 10, when the back of the decorative film 10 is illuminated with light, the light passing through the transparent section 14A of the light-shielding layer 14 forms a graphic symbol 10A on the front surface of the decorative film 10.

[0048] Since the conventional decorative film 10 has both a region with the light-reflecting protruding sections 12 and a region without the light-reflecting protruding sections 12 in a region that overlaps with the transparent section 14A of the light-shielding layer 14, as in Fig. As shown in Figure 5B, uneven illumination of the graphic symbol 10A occurs due to variations in the thickness of the semi-transparent layer 13.

[0049] (Display example for the three-dimensional pattern 103A and the graphic symbol 100A on the decorative cover 100 according to the embodiment) Fig. Figure 6 is a view showing a display example of the three-dimensional pattern 103A and the graphic symbol 100A on the decorative cover 100 according to the embodiment.

[0050] As in Fig. As shown in Figure 6A, in the decorative aperture 100 according to the exemplary embodiment, when the back of the decorative aperture 100 is not illuminated with light, the three-dimensional pattern 103A is visible from the front of the decorative aperture 100. Since the decorative aperture 100 according to the exemplary embodiment has a semi-transparent layer 104, the transparent section 105A of the light-shielding layer 105 is less visible from the front of the decorative aperture 100 at this time.

[0051] Furthermore, as in Fig. 6B shows that, in the decorative aperture 100 according to the embodiment, when the back of the decorative aperture 100 is illuminated with light, the graphic symbol 100A, formed by the light transmitted through the transparent section 105A of the light-shielding layer 105, is displayed on the front surface of the decorative aperture 100.

[0052] Since the light transmittance and film thickness of the semi-transparent layer 104 in the decorative aperture 100 are uniform according to the embodiment, no uneven illumination or lighting of the graphic symbol 100A occurs due to variations in the thickness of the semi-transparent layer 104.

[0053] Although the embodiment of the present invention has been described in detail above, the present invention is not limited to these embodiments, and various changes or modifications may be made within the scope of the present invention as described in the attached claims.

[0054] For example, in the decorative aperture 100 according to the embodiment, the light-shielding layer 105 is not limited to a layer having the transparent section 105A along the outer frame of the graphic symbol, but may have the transparent section 105A along the outer frame of the display area of ​​the display.

[0055] This international application claims priority over Japanese patent application No. 2023-122396, which was filed on July 27, 2023, and the entire contents of that application are hereby incorporated by reference. LIST OF REFERENCE MARKS 100 Decorative Covers 100A Graphic symbol 101 Transparent resin layer 102 Binder layer 103 Translucent substrate 103A Three-dimensional pattern 103B Three-dimensional pattern section 104 Semi-permeable layer 105 Light shielding layer 105A Permeable section 106 Light source QUOTES INCLUDED IN THE DESCRIPTION

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

[0000] JP 6899969

[0004] JP 6405004

[0004] JP 2023-122396

[0055] < / vergleichsbeispiel>

Claims

[1] Decorative aperture, comprising: a transparent resin layer; a translucent substrate designed to be arranged on the reverse side of the transparent resin layer and designed to visually express a three-dimensional pattern created by an uneven surface of the translucent substrate; and a semi-transparent layer designed to be placed on the back side of the translucent substrate and having a contour that matches the uneven surface of the translucent substrate. [2] The decorative cover according to claim 1, which further comprises: a light-shielding layer designed to be arranged on a back side of the semi-transparent layer, having a contour that corresponds to the uneven surface of the translucent substrate, and having a translucent section along an outer frame of a graphic symbol or display area of ​​an advertisement. [3] The decorative cover according to claim 2, which further comprises: a light source located on the back side of the light-shielding layer, wherein Light emitted from the light source passes through the transparent section of the light-shielding layer, the semi-transparent layer, and the translucent substrate to display the graphic symbol or display area of ​​the display on a front surface of the transparent resin layer. [4] The decorative aperture according to any one of claims 1 to 3, wherein the semi-transparent layer has a uniform light transmittance and a uniform film thickness and is applied to the rear surface of the translucent substrate. [5] Manufacturing processes, including: Forming a semi-transparent layer with uniform light transmission and film thickness by screen printing a semi-transparent ink onto the reverse side of the translucent substrate; Forming an uneven surface, perceived as a three-dimensional pattern, on the translucent substrate on which the semi-transparent layer is formed; and Performing an overmolding process to form a transparent resin layer on a front surface of the translucent substrate on which the uneven surface is formed.

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