Method for coating a surface of a trim component main body, trim component for attachment to a motor vehicle, and system for producing a trim component

Abstract

The invention relates to a method for coating a surface (2) of a trim component main body (1), in particular of a motor vehicle, comprising the following method steps: - providing (S2) the trim component main body (1) within a vacuum chamber (8); - applying (S4) a diffusion barrier layer (3) to the surface (2) of the trim component main body (1) in the vacuum chamber (8) in order to inhibit outgassing of volatile substances from the trim component main body (1); and - applying (S5) a decorative layer (4) to the diffusion barrier layer (3) on the surface (2) in a vacuum in the vacuum chamber (8).

Description

[0001] Method for coating a surface of a visible component base body, visible component for covering a motor vehicle and system for producing a visible component

[0002] DESCRIPTION:

[0003] The invention relates to a method for coating a surface of a visible component base body, in particular of a motor vehicle, an associated visible component for cladding a motor vehicle, and an associated system for producing a visible component

[0004] Decorative functional coatings on visible components, especially vehicle interiors and / or exteriors, are currently applied, for example, by painting or electrochemical coating, particularly by galvanic coating. Another manufacturing method is the use of colored base substrates, particularly colored plastic materials.

[0005] The disadvantage of a painting process is that it is very time- and energy-intensive. Furthermore, the production of desired design specifications, such as high-gloss chrome effects, is only partially feasible. Furthermore, compliance with or reproducibility of common quality requirements is only possible with considerable additional effort, particularly through complex post-processing.

[0006] The electroplated chrome coating systems that cover visible components such as mirror housings or various interior trim elements are currently produced using an electrochemical or galvanic coating process. These coating processes are highly toxic and therefore pose an intolerable risk to humans and the environment. Furthermore, the European Union's REACH regulation prohibits the use of electroplated chromium or chromium compounds based on chromium III or chromium hydroxide.

[0007] Chromium VI

[0008] For this reason, coating processes such as physical vapor deposition (PVD) or chemical vapor deposition (CVD), in particular plasma-assisted CVD (PACVD), are already being used as an alternative to electroplating and painting.

[0009] However, one problem with coating using physical or chemical vapor deposition is that substances can outgas from the material of the substrate to be coated, which can chemically react with the coating material. This outgassing can lead to defects and / or undesirable irregularities in the coating, which can have a detrimental effect, particularly on the visual appearance of the visible component.

[0010] The invention is therefore based on the object of providing a coated visible component, the coating of which prevents outgassing from the base body.

[0011] The problem is solved by the subject matter of the independent patent claims. Advantageous developments of the invention are described by the dependent patent claims, the following description, and the figures.

[0012] A first aspect of the invention provides a method for coating a surface of a visible component base body, in particular of a motor vehicle. The method comprises the following steps:

[0013] - Providing the visible component base body within a vacuum chamber; - Applying a diffusion barrier layer to the surface of the visible component base body in the vacuum chamber to inhibit outgassing of volatile substances from the visible component base body; and

[0014] - Applying a decorative layer to the diffusion barrier layer on the surface in a vacuum in the vacuum chamber.

[0015] The result of the method according to the invention can preferably be a visible component comprising the visible component base body and the coating on the surface. The visible component can in particular be a component of the vehicle that is visible to a vehicle occupant inside the motor vehicle and / or a vehicle observer outside the motor vehicle, for example, panels, covers, decorations, or the like.

[0016] The visible component base body can be manufactured or provided from any desired material. The material of the visible component base body is preferably any desired plastic, for example PMMA (polymethyl methacrylate). The material can also be, in particular, metal or a metal-containing compound, or a composite material such as a fiber composite material, e.g., CFRP (carbon fiber reinforced plastic), as well as leather, wood, ceramic, and the like. The visible component base body can take on a shape suitable for a visible component, in particular of a motor vehicle. The visible component base body can furthermore have any desired color and any desired surface finish.

[0017] Using this process, exactly one, a selection of, or all surfaces of the visible component base body can be coated. In particular, the surface can be smooth or rough, as well as flat or curved.

[0018] In particular, the process can include a cleaning process of the

[0019] This should preferably take place outside the vacuum chamber. In particular, the visible component base is degreased and substances that impair wetting are removed. Alkaline release agents and demineralized water are particularly suitable for this purpose, and the visible component base is then dried. The goal of the cleaning process is a clean, residue-free, and dry surface.

[0020] The vacuum chamber in which the visible component base body is provided can, in particular, be sealed pressure-tight, so that a vacuum can be built up within the vacuum chamber, whereby the vacuum can still have a technically conditioned residual pressure, for example of approximately 10' 5 mbar. Accordingly, the visible component base body can be surrounded by a vacuum, in particular a technical vacuum, within the vacuum chamber. To generate the technical vacuum, the vacuum chamber can be evacuated by means of a pump.

[0021] In particular, the vacuum chamber can have multiple zones, each of which can be spatially or physically separated from one another, preferably pressure-tightly separated by means of a vacuum lock. Preferably, provision can be made for each process step to be carried out in a separate zone of the multiple zones. In particular, each of the multiple zones has a station, each station being configured to carry out a respective process step of the process. The multiple, separable zones ensure that contamination between the process steps is prevented.

[0022] Particularly within a vacuum, the effect of the volatile substances outgassing from the visible component base body is amplified. This effect can be inhibited or stopped by the diffusion barrier layer. In a subsequent step, a material is applied or applied to the surface of the visible component base body in the vacuum to form a diffusion barrier layer. The diffusion barrier layer is particularly suitable for inhibiting or blocking the outgassing or diffusion of volatile substances from the material of the visible component base body. Outgassing can be understood, in particular, as a process in which substances in the visible component base body escape from the surface of the visible component base body into the environment in a gaseous state.

[0023] In particular, the diffusion layer inhibits or blocks the outgassing of predetermined volatile substances, for example, substances that typically outgas from the material of the visible component base body. Preferably, the material of the diffusion barrier layer is adaptable or adapted to the volatile substance(s) so that the greatest possible inhibition of outgassing can be achieved. The volatile substances can be, for example, air components, as well as hydrogen, plasticizers, other plastic additives, or the like.

[0024] The diffusion barrier layer may, in particular, comprise a material applied to the surface. The thickness of the diffusion barrier layer may be in the sub-p range. This means that the thickness of the diffusion layer may preferably be less than one micrometer (1 pm).

[0025] Subsequently, a material is applied or deposited onto the diffusion barrier layer to form a decorative layer. The decorative layer can impart optical and / or tactile surface properties to the visible component. The thickness of the decorative layer can be in the sub-p range. This means that the thickness of the decorative layer can preferably be less than one micrometer (1 pm).

[0026] The process has the advantage that a chemical reaction between the material of the decorative layer and / or the material of a subsequent coating and a volatile substance emitted from the material can be inhibited. This allows the coating to be applied evenly on the surface as desired and / or prevents any visible visual impairments on the surface.

[0027] Preferably, the diffusion barrier layer is applied by a first process of physical or chemical vapor deposition.

[0028] Chemical vapor deposition (CVD) is a coating process that uses plasma-assisted, thermally, or electrically induced chemical reactions on the surface of a heated substrate. Reagents are introduced into the substrate in gaseous form. This deposits the diffusion barrier material from the substrate. This can preferably be done under vacuum. Generally, CVD creates thin films or coatings through the dissociation or chemical reactions of gaseous reactants in an activated environment (heat, light, plasma).

[0029] Unlike chemical vapor deposition processes, physical vapor deposition (PVD) transfers the material of the diffusion barrier layer from a substrate into the gas phase, preferably under vacuum. The gaseous material is then directed to the visible component base body to be coated, where it forms the target layer.

[0030] The CVD or PVD process offers the advantage that the material for applying the diffusion barrier layer can be applied evenly over the entire surface of the visible component base body. Thus, even outgassing of the volatile material from the visible component base body can be reliably inhibited if the diffusion barrier layer has a thickness in the sub-p range. Preferably, a protective layer is applied to the decorative layer, which in particular has a hard yet ductile surface finish.

[0031] The protective layer, which can also be referred to as encapsulation, can be designed to be particularly resistant to external influences on the visible component, so that, for example, scratch marks can be prevented or reduced. In particular, the protective layer can serve as protection against mechanical, physical, and chemical damage to the surface, e.g., caused by scratches, stone chips, creatine, UV radiation, weathering, salt, cosmetics, acid exposure, and the like. Furthermore, the protective layer can have the property that, despite plastic deformation of the visible component, the protective layer remains on the decorative layer and advantageously offers permanent protection, so that the desirable visual impression of the visible component is maintained.

[0032] It is preferably provided that the application of the decorative layer is carried out by a second process of physical or chemical vapor deposition, and / or the application of the protective layer is carried out by a third process of physical or chemical vapor deposition.

[0033] In particular, the diffusion barrier layer can first be applied to the base body using PVD or CVD in the vacuum of a first region of the vacuum chamber. Subsequently, the decorative layer can be applied to the diffusion barrier layer using PVD or CVD in the vacuum of a second region of the vacuum chamber. Subsequently, the decorative layer can be applied to the decorative layer using PVD or CVD in the vacuum of a third region of the vacuum chamber.

[0034] This has the advantage that all process steps can take place under vacuum in the vacuum chamber, thus simplifying the process. Another advantage is that the process does not involve any painting or electroplating of the visible component body, either as a base layer or as an outer protective layer. This makes the process particularly environmentally friendly. Furthermore, the process is suitable for the surface coating of visible components, both inside and out, on all types of land, air, and water vehicles.

[0035] Preferably, the diffusion barrier layer comprises parylene and / or spinel and / or derivatives thereof. In particular, the diffusion barrier layer may consist of parylene and / or spinel and / or derivatives thereof.

[0036] Parylene, or polyparaxylene, is produced using CVD. Parylene or its derivatives as a diffusion barrier layer exhibit particularly advantageous properties. Firstly, a diffusion barrier layer containing parylene blocks or inhibits the outgassing of volatile substances, even at a diffusion barrier layer thickness in the sub-p range. Furthermore, parylene exhibits good mechanical properties and very good dielectric properties, as well as a lubricious surface. Parylene is biocompatible, transparent, temperature-stable, chemically inert, and solvent-resistant. The coating is highly surface-conformal, meaning even difficult-to-access areas (e.g., internal surfaces or undercuts) can be coated. Porous substrates can also be coated.

[0037] Spinel is a complex magnesium-aluminum oxide. Due to the main component of the ceramic, spinel, such a layer advantageously possesses high hardness and high wear resistance. Preferably, the surface of the visible component base body is subjected to plasma activation before applying the diffusion barrier layer.

[0038] Plasma activation of the surface of the visible component base body can increase its surface energy, resulting in the formation of polar molecular end groups. These serve as attachment points for coating materials and ensure better adhesion. Plasma activation can modify the surface and build up surface energy, resulting in significantly improved surface wettability.

[0039] Preferably, the respective process steps are carried out continuously within the vacuum chamber in a flow production process. In particular, the process steps are not synchronized. The process steps of the process can thus be carried out without interruption.

[0040] In particular, the application of the respective layers can be carried out in a vacuum, while the visible component base body moves via a conveyor system in continuous production at a feed rate to be defined depending on the time required for each application step. In particular, the visible component base body can only be brought to a standstill upon leaving the vacuum chamber or at the end of the process.

[0041] In other words, the respective process steps are understood to mean the provision of the visible component base body within the vacuum chamber, preferably the plasma activation of the surface, the application of the diffusion barrier layer to the surface of the visible component base body, the application of the decorative layer to the diffusion barrier layer, and optionally the application of a protective layer to the decorative layer.

[0042] Short transport routes and the elimination of intermediate storage in flow production minimize waiting or idle times for the visible component or the visible component base. This results in short lead times, which have a positive impact on efficiency.

[0043] The invention also encompasses combinations of the features of the described embodiments. The invention therefore also encompasses implementations that each comprise a combination of the features of several of the described embodiments, unless the embodiments are described as mutually exclusive.

[0044] A second aspect of the invention provides a visible component for cladding a motor vehicle, comprising a visible component base body and a coating on the visible component base body. The coating comprises a diffusion barrier layer for inhibiting the outgassing of volatile substances from the visible component base body and a decorative layer applied or applied thereover.

[0045] In particular, the visible component can be produced by the method according to the first aspect of the invention by coating the visible component base body by the respective method steps.

[0046] In particular, components of the motor vehicle, either on the outside or in the interior of the vehicle, can be covered by the visible component. Such components can be, for example, the cover of a side mirror on the outside of the vehicle or the cover of an ashtray in the interior of the vehicle.

[0047] Preferably, the coating comprises a protective layer that is applied or applied over the decorative layer. This can preferably be applied to the decorative layer by a method step according to a preferred embodiment. The invention also includes further developments of the visible component according to the invention that have features as already described in connection with the further developments of the method according to the invention. For this reason, the corresponding further developments of the visible component according to the invention are not described again here.

[0048] A third aspect of the invention provides a system for producing a visible component according to the invention by means of a surface coating method according to the invention. The system comprises, firstly, the vacuum chamber. The system further comprises a plurality of stations within the vacuum chamber, each of the plurality of stations being configured to perform a respective method step of the method. The system further comprises a flow device configured to convey the visible component to be coated between the plurality of stations.

[0049] The system can, in particular, be a production facility or a section of a higher-level production facility. The stations of the facility each comprise the components required to carry out a respective process step. The flow device can, for example, be a conveyor belt.

[0050] Exemplary embodiments of the invention are described below. Shown are:

[0051] Fig. 1 shows a cross section through a layer structure of a visible component according to the invention according to a preferred embodiment;

[0052] Fig. 2 is a flowchart of a method according to the invention according to a preferred embodiment;

[0053] Fig. 3 is a schematic representation of a system for producing a visible component according to a preferred embodiment. The exemplary embodiments explained below are preferred embodiments of the invention. In the exemplary embodiments, the described components of the embodiments each represent individual features of the invention that can be considered independently of one another, each of which also further develops the invention independently of one another. Therefore, the disclosure is intended to encompass combinations of the features of the embodiments other than those illustrated. Furthermore, the described embodiments can also be supplemented by further features of the invention already described.

[0054] In the figures, the same reference symbols designate elements with the same function.

[0055] Fig. 1 shows a cross-section through a layered structure of a visible component 6 according to the invention, according to a preferred embodiment. The visible component 6 comprises a visible component base body 1, as well as a coating on a surface 2 of the visible component base body 1, which coating comprises a plurality of layers 3, 4, 5 or consists of these layers 3, 4, 5. The respective thicknesses of the layers 3, 4, 5 shown here are chosen solely for clarity. In particular, the thicknesses can be different from one another.

[0056] A diffusion barrier layer 3 can first be applied to the surface 1, which can be cleaned in particular by a cleaning process, so that outgassing of volatile substances from a material of the visible component base body 1 through the surface 2 into the environment can be inhibited or prevented.

[0057] A decorative layer 4 can be applied to the diffusion barrier layer 3. When applying the decorative layer 4, the diffusion barrier layer 3 can, in particular, prevent volatile substances from escaping from the visible component base body 1, which could create a surface defect in the decorative layer 4 or chemically react with a material of the decorative layer 4.

[0058] A protective layer 5 can optionally be applied to the decorative layer 4, which can serve to protect against mechanical, physical and chemical damage to a surface of the protective layer 5 or the decorative layer 4, e.g. due to scratches, stone chips, creatine, UV radiation, weather influences, salt, cosmetics, acid effects and the like.

[0059] Fig. 2 shows a flow diagram of a method according to the invention in accordance with a preferred embodiment. In a first step S1, which can be optional for the method according to the invention, the visible component base body 1 is cleaned and dried by means of the cleaning process. In a second method step S2, the visible component base body is provided within a vacuum chamber 8, wherein a vacuum can technically be provided within the vacuum chamber 8. In a subsequent, third step S3, which is optional for the method according to the invention, the surface 2 of the visible component base body 1 can be subjected to plasma activation. In a subsequent fourth step S4, the diffusion barrier layer 3 is applied to the surface 2 of the visible component base body 1 in the vacuum chamber 8 to inhibit outgassing of volatile substances from the visible component base body 1.In a subsequent fifth step S5, the decorative layer 4 is applied to the diffusion barrier layer 3 on the surface 2 in a vacuum in the vacuum chamber 8. In a subsequent, sixth step S6, a protective layer 5 can optionally be applied to the decorative layer 4, which in particular has a hard and ductile surface finish, in accordance with the method according to the invention.

[0060] Fig. 3 shows a schematic representation of a system 7 for producing a visible component 6 according to a preferred embodiment. The system 7 comprises at least the vacuum chamber 8 with a plurality of stations 13-17 within the vacuum chamber 8, as well as a flow device 9 configured to transport the visible component to be coated between the plurality of stations 10-19. The plurality of stations 13-17 can, for example, each be assigned to a region of the vacuum chamber 8, wherein the regions can each be separated from one another in a pressure-tight manner. In a first station 10, for example, the visible component base body 1 or a plurality of visible component base bodies 1 can be provided outside the vacuum chamber 8, for example on a suspension configured for this purpose. By means of the flow device 9, the visible component base body 1 can be transported to the second station 11 and to all further stations 12-19.

[0061] In the second station 11, the visible component base body 1 can be subjected to the cleaning process. A third station 12 can, for example, represent a front vacuum lock for the transition from an environment under normal pressure to the preferably evacuated vacuum chamber 8, in which a vacuum can prevail. In a fourth station 13, for example, the visible component base body 1 can be provided within the vacuum chamber 8. The visible component base body 1 can then be conveyed by means of the flow device 9, for example, to a fifth station 14. In the fifth station 14, the surface 2 of the visible component base body 1 can be subjected to plasma activation. In a subsequent sixth station 15, the diffusion barrier layer 3 can be applied to the surface 2 of the visible component base body 1. In a subsequent seventh station 16, the decorative layer 4 can, for example, be applied to the diffusion barrier layer.Finally, the protective layer 5 can be applied to the decorative layer 4 in an eighth station 17 within the vacuum chamber 8.

[0062] At the end of the vacuum chamber 8, a ninth station 18 can follow in the form of a rear vacuum lock for the transition from the vacuum chamber 8 to the ambient atmosphere at normal pressure. At a tenth station 19, the visible component 6, which can correspond to the coated visible component base body 1, can be prepared for further processes. For example, several stations can be combined into one station. It is also conceivable that additional stations could be provided.

[0063] Overall, the examples show how a method for coating a surface of a visible component base body, a visible component for cladding a motor vehicle and a system for producing a visible component can be provided.

Claims

PATENT CLAIMS:

1. Method for coating a surface (2) of a visible component base body (1), in particular of a motor vehicle, comprising the process steps: - Provision (S2) of the visible component base body (1 ) within a vacuum chamber (8); - Applying (S4) a diffusion barrier layer (3) to the surface (2) of the visible component base body (1) in the vacuum chamber (8) to inhibit outgassing of volatile substances from the visible component base body (1); and - Applying (S5) a decorative layer (4) to the diffusion barrier layer (3) on the surface (2) in a vacuum in the vacuum chamber (8).

2. Method according to claim 1, characterized in that the application of the diffusion barrier layer (3) is carried out by a first process of physical or chemical vapor deposition.

3. Method according to claim 1 or 2, characterized in that a protective layer (5) is applied to the decorative layer (4) (S6), which in particular has a hard and ductile surface texture.

4. Method according to claim 3, characterized in that the application of the decorative layer (4) is carried out by a second process of physical or chemical vapor deposition, and / or the application of the protective layer (5) is carried out by a third process of physical or chemical vapor deposition. A method according to any one of the preceding claims, characterized in that the diffusion barrier layer (3) comprises parylene and / or spinel and / or their derivatives. A method according to any one of the preceding claims, characterized in that the surface (2) of the visible component base body (1) is subjected to plasma activation (S3) before the diffusion barrier layer (3) is applied. A method according to any one of the preceding claims, characterized in that the respective process steps (S2, S3, S4, S5, S6) are carried out continuously in a flow production process within the vacuum chamber (8). Visible component (6) for the fairing of a motor vehicle, which - a visible component base body (1 ) and - has a coating on the visible component base body (1), characterized in that the coating - a diffusion barrier layer (3) to inhibit outgassing of volatile substances from the visible component base body (1), and - comprises a decorative layer (4) applied above it. Visible component (6) according to claim 8, characterized in that the coating comprises a protective layer (5) which is applied above the decorative layer (4). Apparatus (7) for the production of a visible component (6) according to one of claims 8 or 9 by means of a method according to one of claims 1 to 7, - comprising the vacuum chamber (8), characterized by - several stations within the vacuum chamber (8), each station of the several stations being set up to carry out a respective process step (S2, S3, S4, S5, S6) of the process, - a flow device (9) which is set up to transport the visible component (6) to be coated between the several stations.

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