METHOD FOR PRODUCING A DECORATIVE COMPONENT WITH A RAISED EMBOSSED VISIBLE SURFACE

Description

[0001] A method for manufacturing a decorative component with a raised, embossed visible surface is described. The decorative component may, for example, have a decorative material layer, in particular a natural material layer such as leather or veneer. Furthermore, a decorative component manufactured by the method is described.

[0002] To emboss leather or textiles, they are typically clamped in a frame and placed under a press. The design is then embossed into the workpiece using heat and pressure. The process parameters determine the durability of the embossing. The higher the pressure and temperature, or the more moisture the leather contains, the more durable and detailed the resulting impression.

[0003] To create intricate textures in wood and / or leather, propane gas stamps or electric branding irons are used. The stamp is heated to the desired temperature and pressed into the material for a defined period. This method can only produce concave impressions; it does not create any raised motifs in the wood.

[0004] The methods known in the prior art have a number of disadvantages. For example, they generally do not achieve high dimensional stability of the embossing, and the embossing tools used, typically made of steel or brass (EDM or milled), require a costly manufacturing process. Furthermore, the known methods do not allow for motif embossing in wood; only concave embossings are currently possible. The high cost of the embossing tools and their long manufacturing time result in limited product flexibility. Additionally, high storage costs arise when a large number of customized tools are required.

[0005] Documents DE 10 2005 006541 A1, WO 2014 / 193961 A1, US 2008 / 141569 A1, WO 2015 / 120429 A1, DE 36 07 647 A1, DE 10 2008 059719 A1, EP 2 886 367 A1 and US 5 849 238 A disclose various prior art technical solutions relating to the manufacture of decorative components.

[0006] It is an objective of at least some embodiments to specify a method for manufacturing a decorative component with a raised, embossed visible surface that exhibits high dimensional stability and whose tactile properties can be adapted to individual customer requirements without significant effort. A further objective of at least some embodiments is to specify a decorative component manufactured by the method.

[0007] These tasks are solved by a method and a device according to the independent claims. Advantageous embodiments and further developments are described in the dependent claims, the following description, and the drawings.

[0008] The process described here for manufacturing a decorative component with a raised, embossed surface requires an embossing device and at least one layer of decorative material. The embossing device comprises an embossing die and an embossing counter-die. The decorative material layer has a thickness between 0.6 mm and 5 mm.

[0009] The decorative material layer is positioned between the embossing die and the embossing counter-die such that a visible surface of the decorative material layer faces the embossing die, and a reverse surface of the decorative material layer, opposite the visible surface, faces the embossing counter-die. An embossing process is then carried out using the embossing device, so that after the embossing process, the decorative material layer has a raised area on the visible surface and a corresponding recessed area on the reverse surface. Preferably, the raised area on the visible surface is created during the same embossing process as the recessed area on the reverse surface. Subsequently, an insert element is placed in the recessed area to stabilize the raised area. This insert element improves the dimensional stability of the embossing and the raised area of ​​the visible surface.

[0010] The method described here allows for a combination of raised and recessed motifs, including surface texture. In particular, a combination of convex and concave and / or embossed or densified structures can be achieved.

[0011] According to a further embodiment, the described method creates, in addition to the raised area on the visible surface of the decorative material layer, a further raised area and / or at least one recessed area on the visible surface of the decorative material layer. Furthermore, a plurality of additional, preferably spatially separated, raised areas and / or a plurality of additional, preferably spatially separated, recessed areas on the visible surface of the decorative material layer can be created. Thus, a raised and / or deep-drawn or embossed convex and / or concave pattern can be created on the visible surface of the decorative material layer. This allows the design of the decorative component to be individually adapted to customer requirements. For example, the raised or recessed areas on the visible surface can be produced by the same embossing process.The raised areas on the visible surface can preferably all be stabilized by arranging an insert element, as described above.

[0012] According to a further embodiment, one or more indentations are created in the visible surface of the decorative material layer. In the area of ​​the indentations, the decorative material layer preferably has a lesser thickness perpendicular to its surface than in directly adjacent areas. The indentations can be formed, for example, in the area of ​​the raised area and / or in a flat area surrounding the raised area. The indentations can be created, for example, by the embossing process by which the raised area is formed on the visible surface. Alternatively, the indentations can be produced before or after this embossing process by means of one or more further embossing processes. The indentations can be used, for example, to represent patterns, lettering, logos, or the like on the visible surface.

[0013] According to a further embodiment, the insert element has a surface contour that is adapted to the surface contour of the decorative material layer in the recessed area. Preferably, in particular, a surface of the insert element associated with the recessed area of ​​the back surface is adapted to the surface contour of the recessed area. For example, the insert element can be arranged in the recessed area in such a way that, after the insert element has been arranged, there are no gaps between the decorative material layer and the insert element.

[0014] According to another embodiment, the insert element is manufactured using an additive manufacturing process. For example, the insert element can be produced by selective laser melting, selective laser sintering, stereolithography, multi-jet fusion, continuous liquid interface production, or fused deposition modeling. Additive manufacturing allows for cost-effective production of the insert element, and its properties can be precisely controlled. Alternatively, the insert element can be manufactured using a casting process, such as silicone casting.

[0015] According to a further embodiment, the insert element has a plurality of recesses on its interior. These recesses preferably represent cavities within the insert element. For example, the insert element can have a cellular structure with a plurality of recesses. The size of the individual cells in the cellular structure can be uniform or vary, depending on the required compression hardness of the insert element. The cellular structure of the insert element can be produced, in particular, by an additive manufacturing process. The recesses of the insert element can also be produced, or additionally produced, by using subsequently fractured hollow glass spheres, which are, for example, embedded in a polymer matrix.

[0016] The haptic properties of the raised area of ​​the visible surface can advantageously be individually adapted to customer requirements, for example by varying the compression hardness. Furthermore, it is possible to improve the ergonomic aspects of embossing, for example with regard to use on a driver's seat, an armrest, or a headrest.

[0017] The insert element is attached in the recessed area. The insert element is glued into the recessed area. Preferably, the surface of the insert element corresponding to the recessed area of ​​the back surface of the decorative material layer is bonded to the decorative material layer.

[0018] According to a further embodiment, the insert element has a modulus of elasticity of less than or equal to 5.0 GPa. Preferably, the insert element has a modulus of elasticity of less than or equal to 0.5 GPa, and more preferably of less than or equal to 50 MPa.

[0019] Furthermore, the insert element contains or consists of a thermoplastic elastomer. It can also be made of a thermoplastic material, such as polyurethane. Additionally, it can be made of a thermosetting material. Advantageously, the compression hardness of the insert element can be adjusted according to haptic requirements. It is also possible for the insert element to contain silicone.

[0020] Furthermore, the decorative material layer is a natural material layer, i.e., a layer made of a natural material. The natural material layer contains or consists of leather. Additionally, the decorative material layer can contain a fabric, for example, a microfiber fabric such as Alcantara. According to another embodiment, the embossing die and / or the embossing matrix are manufactured using an additive manufacturing process. For example, the embossing die and / or the embossing matrix can be manufactured by selective laser melting, selective laser sintering, stereolithography, multi-jet fusion, continuous liquid interface production, or fused deposition modeling. This allows for a high degree of design freedom and a wide variety of variants at low manufacturing costs.Furthermore, the layer-by-layer construction of embossing tools manufactured using additive manufacturing processes allows for particularly good creation of height gradients between raised and recessed areas on the visible surface. Additionally, the embossing die and / or the embossing counter-die can be milled and / or eroded.

[0021] According to a further embodiment, the embossing die and / or the embossing male die have at least one channel and / or a porous structure for guiding a medium or for temperature control and / or conditioning. During the embossing process, a first medium is preferably guided to a tool surface of the embossing die and / or the embossing male die. The first medium can, for example, be a liquid or gaseous medium, such as water, steam, or air. Preferably, the first medium has a high temperature. By guiding the first medium to the tool surface, it can, for example, increase the temperature of the decorative material layer without directly contacting it, so that the decorative material layer can be more easily formed due to the heat input.Alternatively, the first medium can come into direct contact with the decorative material layer when it is directed to the tool surface, for example, by vaporizing the decorative material layer with steam. This allows the decorative material layer to remain ductile during the molding process. Once the desired shape of the decorative material layer has been achieved, the supply of the first medium can be stopped.

[0022] According to a further embodiment, after the first medium has been supplied to the tool surface of the embossing die and / or the embossing male die, a second medium is supplied to the tool surface of the embossing die or the embossing male die. The second medium preferably has a lower temperature than the first medium. The second medium can again be a gaseous or liquid medium, such as air, steam, or water. The second medium can either be supplied to the vicinity of the decorative material layer without touching it, or alternatively, when supplied to the tool surface, it can directly contact the decorative material layer. The desired shape of the decorative material layer can be fixed by means of the second medium.

[0023] The process described here enables a high degree of product flexibility at low manufacturing costs. Furthermore, it reduces storage costs for disposable tools. The process is also characterized by very short lead times and comparatively low tooling costs, allowing for better responsiveness to individual customer requirements.

[0024] Furthermore, a decorative component manufactured using a method described herein is specified. The decorative component may have one or more features of the aforementioned embodiments. The features mentioned previously and subsequently may refer both to the described method and to the decorative component manufactured using the method.

[0025] According to at least one embodiment, the decorative component comprises a decorative material layer with a visible surface and a reverse surface opposite the visible surface. The visible surface has a raised area. The reverse surface has a recessed area opposite the raised area of ​​the visible surface. Furthermore, the decorative component includes an insert element, which is arranged in the recessed area to stabilize the raised area. Preferably, the insert element is fixed in the recessed area by means of an adhesive bond. The decorative component is an interior trim part of a vehicle's passenger compartment.

[0026] According to another embodiment, the insert element is manufactured using an additive manufacturing process. The insert element comprises or consists of a thermoplastic elastomer, such as polyurethane. Depending on the material and the design of the structures, the compliance or elasticity of the insert element can be adapted to individual customer requirements or application areas. This can be achieved, for example, by a cell-like structure of the insert element, the properties of which vary depending on the pre-defined cell size, cell geometry, cell wall thickness, and / or number of cells.

[0027] According to a further embodiment, the decorative material layer can have one or more recessed embossings on the visible surface. In the area of ​​the recessed embossings, the decorative material layer preferably has a lesser thickness than in adjacent areas. The recessed embossing(s) can be formed in the raised area and / or in flat areas of the visible surface.

[0028] Further advantages and advantageous embodiments of the method and decorative component described here will become apparent from the following in conjunction with the Figures 1 to 5 described embodiments. They show: Figs. 1 and 2 are schematic representations of a method described here for producing a decorative component with a raised embossed visible surface according to one embodiment, Figs. 3 to 6 are schematic representations of sectional views of decorative components produced by means of the method described here according to various embodiments, and Fig. 7 is a schematic representation of an inlay element according to another embodiment.

[0029] In the exemplary embodiments and figures, identical or similarly functioning components may be provided with the same reference numerals. The illustrated elements and their relative sizes are generally not to scale. Rather, individual elements may be exaggeratedly thick or oversized for clarity and / or clarity.

[0030] The Figures 1 and 2The process described here for manufacturing a decorative component with a raised, embossed surface is shown in two different perspective views. The decorative component is part of a vehicle's interior trim.

[0031] The process provides a decorative material layer 1 and an embossing device 4, comprising an embossing die 41 and an embossing matrix 42. The embossing die 41 and the embossing matrix 42 are preferably manufactured by an additive manufacturing process, such as selective laser melting, selective laser sintering, stereolithography, multi-jet fusion, continuous liquid interface production, or fused deposition modeling.

[0032] The decorative material layer 1 is positioned between the embossing die 41 and the embossing die 42 such that a visible surface 2 of the decorative material layer 1 faces the embossing die 41, and a reverse surface 3 of the decorative material layer 1, opposite the visible surface 2, faces the embossing die 42. An embossing process is then carried out using the embossing device 4, so that after the embossing process, the decorative material layer 1 has a raised area 21 and a flat area 22 surrounding the raised area on the visible surface 2, as well as a corresponding recessed area 31 on the reverse surface 3. An insert element (not shown) is then placed in the recessed area 31 to stabilize the raised area 21. The insert element is secured in the recessed area 31 by gluing it into the recessed area 31.

[0033] The Figure 3Figure 1 shows a schematic cross-sectional view of a decorative component 100, which is manufactured using the method described herein. The decorative component 100 has a decorative material layer 1, which has a visible surface 2 and a reverse surface 3 opposite the visible surface 2. A raised area 21 is formed on the visible surface 2, and a recessed area 31 is formed opposite it on the reverse surface 3. The raised area 21 and the recessed area 31 are preferably formed by means of an embossing device 4, which may in particular have an embossing die 41 and an embossing die 42. An insert element 5 is arranged in the recessed area 31 to stabilize the raised area 21. The insert element 5 is glued into the recessed area 31.

[0034] The insert element 5 is preferably manufactured by an additive manufacturing process. For example, the insert element 5 can be manufactured by selective laser melting, selective laser sintering, stereolithography, multi-jet fusion, continuous liquid interface production, or fused deposition modeling. The insert element 5 can, for example, consist of a thermoplastic elastomer, such as polyurethane.

[0035] The insert element 5 has a surface contour 51 on the surface facing the rear surface 3, which is adapted to the surface contour 33 of the rear surface 3 in the recessed area 31. Preferably, the insert element 5 is positively connected to the rear surface 3 of the decorative material layer 1. A surface of the insert element 5 facing away from the recessed area 31 preferably terminates flush with the flat area 32 of the rear surface 3.

[0036] In the Figure 4A sectional view of a decorative component 100 described herein, according to a further embodiment, is shown. In contrast to the one in the Figure 3 In the illustrated embodiment, the decorative component 100 has recessed embossings 23 on the visible surface 2. In this embodiment, the recessed embossings 23 are formed particularly in the flat area of ​​the visible surface 2. In the areas of the recessed embossings 23, the decorative material layer 1 has a lesser thickness than in adjacent areas. The recessed embossings 23 formed on the visible surface 2 can be produced in the same process step in which the raised area 21 and the opposite recessed area 31 are created.

[0037] The Figure 5 shows a further embodiment of a decorative component 100, wherein, in contrast to the embodiment according to Figure 3At least one indentation 23 is formed in the raised area 21 of the visible surface 2. In the area of ​​the indentation 23, the decorative material layer 1 has a lesser thickness than in adjacent areas.

[0038] In the Figure 6 A sectional view of a decorative component 100 described herein, according to a further embodiment, is shown. In contrast to the one in the Figure 3 In the illustrated embodiment, the decorative material layer 1 is bonded to a substrate material 6. The decorative material layer 1 and the substrate material 6 preferably completely enclose the insert element 5. Preferably, there are no gaps between the insert element 5 and the substrate material 6. For example, the substrate material 6 can be a mounting surface or a cushioning material.

[0039] The Figure 7Figure 1 shows a schematic representation of an inlay element 5, which has a cell structure 53. The cell structure 53, which has a multitude of recesses 52 forming cavities inside the inlay element 5, allows for the targeted adjustment of the compression hardness and haptic properties of the raised area 21 of the visible surface 2 of the decorative material layer 1. The recesses 52 can be created, for example, during the manufacturing process of the inlay element 5, particularly if the inlay element 5 is produced by an additive manufacturing process. Alternatively, the recesses 52 can be formed by subsequently broken glass hollow spheres.

[0040] The features described in the illustrated embodiments can also be combined according to further embodiments. Alternatively or additionally, the embodiments shown in the figures can have further features according to the embodiments described in the general description. Reference symbol list

[0041] 1 Decorative material layer 2 Visible surface 21 Raised area 22 Flat area 23 Recessed embossing 3 Back surface 31 Recessed area 32 Flat area 33 Surface contour 4 Embossing device 41 Embossing die 42 Embossing die 5 Inlay element 51 Surface contour 52 Recess 53 Cell structure 6 Carrier material 100 Decorative component

Claims

1. Method for producing a decorative component (100), which is designed as an interior trim part of a passenger cabin of a vehicle and has a visible surface (2) embossed in a raised manner, said method comprising the following steps: - providing an embossing device (4) which has a female embossing mould (41) and a male embossing mould (42), - providing at least one decorative material layer (1) having a thickness between 0.6 mm and 5 mm, wherein the decorative material layer (1) comprises leather or consists of leather, - disposing the decorative material layer (1) between the female embossing mould (41) and the male embossing mould (42) in such a manner that a visible surface of the decorative material layer (1) faces the female embossing mould (41), and a reverse face (3) of the decorative material layer (1) that is opposite the visible surface (2) faces the male embossing mould (42), - carrying out an embossing procedure by means of the embossing device (4) such that the decorative material layer (1) after the embossing procedure has a raised region (21) on the visible surface (2) and an opposite depressed region (31) on the reverse face (3), - producing an insert element (5) by an additive manufacturing method, wherein the insert element (5) after production has a cellular structure (53) which is generated by the additive manufacturing method, wherein the insert element comprises a thermoplastic elastomer, and - disposing the insert element (5) in the depressed region (31) for stabilizing the raised region (21), wherein the insert element (5) is adhesively bonded into the depressed region (31).

2. Method according to Claim 1, wherein the insert element (5) has a surface contour (51) which is adapted to the surface contour (33) of the decorative material layer (1) in the depressed region (31).

3. Method according to one of the preceding claims, wherein the insert element (5) has a multiplicity of recesses (52) in the interior.

4. Method according to one of the preceding claims, wherein the insert element (5) has a modulus of elasticity of less than or equal to 5.0 GPa, preferably of less than or equal to 0.5 GPa.