Sublimation for customizing automotive vehicle wraps

Abstract

The invention relates to a method for decorating a body panel with a supporting surface on a motor vehicle; the decoration method comprising the following steps: a) supplying or manufacturing (100) the body panel, such as an exterior body part; b) applying (102) a paint film to the body panel; c) applying (104) a varnish film to the supporting surface of the body panel; and d) printing (106) a decorative layer by ink sublimation against the supporting surface, said ink passing through the varnish film obtained following step c) application of the varnish film. Figure to be published with the abbreviation: Figure 1

Description

Title of the invention: Sublimation for the personalization of automotive vehicle coatings

[0001] The invention relates to the custom decoration of visible parts of a motor vehicle. More specifically, the invention relates to a method for decorating a body panel of a motor vehicle. The invention also relates to a motor vehicle.

[0002] In order to personalize a motor vehicle in a specific and potentially unique way, it is advantageous to add local decoration. This enhances the perceived quality of the motor vehicle. However, small-scale decoration must be integrated into a large-scale production process to optimize costs.

[0003] There are various techniques for customizing the appearance of a motor vehicle. These include applying paint using a stencil and applying adhesives. However, these techniques require the application of protective coatings, followed by their removal. Furthermore, they often result in localized areas of excess thickness, which detracts from the overall appearance. In addition, they require further heat treatment. Finally, certain body geometries are inherently incompatible. Resistance to ultraviolet radiation and abrasion reduces the lifespan of a decoration.

[0004] To meet certain constraints, the sublimation printing process is known. This method reduces labor time and is quickly implementable.

[0005] Document FR2684046A1 describes a sublimation decoration process for an object. It consists of: - using as a sublimable ink support a material sufficiently extensible to adapt to the shape of the object to be decorated without risk of damaging the decoration to be sublimated; - wrapping the object in the ink support so that all its faces are covered; - placing the assembly in a vacuum machine known per se, which is itself introduced into a heated space to cause the transfer of the decoration onto all faces of the object to be decorated.

[0006] US patent US9446599B2 describes an automated product sublimation process that allows for point-of-sale customization of sublimation parameters in a retail environment. A thermal sublimation transfer printing system is configured to print one or more images onto a transfer medium, and then position the medium on a substrate A. The selected product is positioned on top of the medium. The system is configured to automatically determine, via a processor, one or more temperatures and durations of a single thermal cycle to enhance the image(s) on the selected product.

[0007] Document DE102007017444B4 describes a radiator grille with a support and several slats individually inserted into the support, each slat being formed by an overmolded film. A front rail and a rear rail are fixed in the support to receive the slats.

[0008] Document EP1439094B1 describes an exterior vehicle part comprising a decorative film. The external component consists of an injection-molded skin of a transparent or translucent thermoplastic material extending in two perpendicular directions, with a thinner layer of decorative film applied to its inner surface and attached by adhesive. The skin may be colored, contain opaque particles such as glitter, or have opaque areas created by painting, pad printing, or the application of opaque materials.

[0009] Document FR2962941B1 describes a method for printing any type of design on a motor vehicle convertible top in order to personalize it according to the owner's wishes. The method consists of printing a design onto transfer paper, then sublimating said design onto a coated high-tenacity polyester fabric, which is itself bonded to a polyamide fabric by inserting a technical foam. The printed fabric is then used as the outer surface of the convertible top, and the polyamide fabric serves as the inner surface.

[0010] Document WO9962722A8 describes a method for applying a decoration to the surface of an object by sublimation ink printing using, as an ink support or transfer sheet, a heat-shrink film printed with a sublimation ink decoration.

[0011] US patent 11453202B2 describes a thermoformable decorative material for automotive interiors comprising: a decorative layer including a textile substrate; a digitally printed design disposed on at least one side of the textile substrate and comprising a dispersion ink and / or a pigment ink; and a superimposed adhesive coating applied to the digitally printed design. The superimposed adhesive coating includes an adhesive comprising polyurethane and / or polyacrylate.

[0012] The invention aims to address at least one of the problems or drawbacks encountered in the prior art. In particular, the invention aims to increase the durability of a decorative layer on a body panel of a motor vehicle. The invention also aims to optimize the durability, homogeneity, cost, and speed of application of a decorative layer on a body panel of a motor vehicle.

[0013] According to a first aspect, the invention proposes a method for decorating a support surface of a motor vehicle body part, the decoration method comprising the following steps: a) supplying or making a body part; d) printing a decorative layer by sublimation of ink against the support surface; remarkable in that prior to step d) printing, the decoration method further comprises a step c) application of a varnish film on the body part; at step d) printing, said ink passes through the varnish film obtained following step c) application of the varnish film.

[0014] The invention combines a decorative layer at the base of a varnish film. On the one hand, the presence and thickness of the varnish film protect the decorative layer; and on the other hand, it allows the decorative layer to benefit from the adhesion of the varnish film. These aspects combine to prolong the appearance of the decorative layer, thus guaranteeing the perceived quality over the long term.

[0015] Document WO200437555A1 describes a process for obtaining a decorative marking with good adhesion, and therefore durability. It essentially consists of pre-varnishing the surface to be decorated, then applying a thermal printing process to the varnished surface using sublimation paper pre-printed with the chosen design. This process is applicable to the decorative marking of school and office supplies, for example, to decorate scissor blades. This document does not provide a solution for the automotive field.

[0016] Preferably, prior to step c) application of the varnish film, the decoration process includes a step b) application of a paint film on the envelope piece; step d) sublimation printing reaching the paint film through the varnish film.

[0017] Preferably, the envelope part is an exterior body part, step c) application of the varnish film includes application by a sprayer, said varnish comprising a hardener; preferably, the varnish has a first density, the ink comprises a second density greater than the first density.

[0018] Preferably, during step d) printing, an inflated bag exerts pressure against the envelope piece.

[0019] Preferably, step d) printing includes applying a pressure of 100 g / m2 to 200 g / m2 to the envelope piece.

[0020] Preferably, in step d) printing, the ink includes a sublimation temperature, step d) printing being carried out at a temperature between 100% and 130% of said sublimation temperature; preferably, step d) printing includes a temperature between 80°C and 120°.

[0021] Preferably, the envelope piece includes an edge with two opposite faces, a slice connecting the opposite faces, at step d) printing, the decorative layer covers the slice and the opposite faces.

[0022] Preferably, the envelope piece includes a rib; in step d) printing, the decorative layer covers said rib.

[0023] Preferably, step c) application of the varnish film is a first step of applying a first varnish film with a first thickness; following step d) printing, the decoration process further includes a step e) application of a second varnish film with a second thickness less than the first thickness.

[0024] Preferably, step d) printing includes a substep d1) supplying a transfer sheet; a substep d2) printing a decoration on the transfer sheet; a substep d3) applying the transfer sheet to the envelope piece; a substep d4) heating the transfer sheet against the envelope piece; a substep d5) removing the transfer sheet.

[0025] Preferably, in step d) printing, the decorative layer comprises several colors.

[0026] Preferably, step d) printing is repeated in order to implement several decorative layers stacked one on top of the other.

[0027] Preferably, prior to step d) printing, the decoration process includes a step of drying and degassing the varnish film; preferably, the envelope piece comprises metal, plastic, wood or ceramic.

[0028] Preferably, step d) printing is carried out under vacuum.

[0029] Preferably, following step d) printing, the decorative layer is within the thickness of the varnish film.

[0030] Preferably, in step d) printing, the envelope piece includes a rib and / or a rebate covered by the decoration.

[0031] Preferably, following step d) printing, the decoration process further includes a step f) polishing of the varnish film.

[0032] Preferably, following step c) application, the varnish film has a porosity with a network of pores passing through said varnish film; in step d) printing, said ink passes through the varnish film via said network of pores.

[0033] Preferably, the envelope part is a motor vehicle bumper skin.

[0034] Preferably, the envelope part is an inner envelope part or an outer envelope part.

[0035] According to another aspect, the invention proposes a method for decorating a body part with a motor vehicle support surface; the decoration method comprising the following steps: • a) supply or production of the envelope part; • c) application of a varnish film on the support surface of the envelope part; remarkable in that, following step c) application, the decoration process includes a step • d) printing of a decorative layer by ink sublimation against the support surface through the varnish film obtained following step c) application of the varnish film.

[0036] Each feature introduced by the expression "preferably" given in relation to one of the aspects of the invention applies to all other aspects of the invention.

[0037] The invention will be well understood and other aspects and advantages will become clear upon reading the following description, given with reference to the attached figures listed below.

[0038] Fig. 1 illustrates a diagram of a method for decorating a part of the bodywork of a motor vehicle according to the invention.

[0039] Figure 2 is a cross-section of a piece of envelope during a printing step of a decorative coating for motor vehicles according to an embodiment of the invention.

[0040] Figure 3 is a cross-section of a piece of casing with a decorative layer for motor vehicle according to an embodiment of the invention.

[0041] In the following description, the term "include" is synonymous with "include" and is not limiting in that it permits the presence of other elements in the motor vehicle or other steps in the decoration process to which it relates. It is understood that the term "include" includes the terms "consist of." The terms "external" and "internal" shall respectively refer to what is directed outward and inward toward the vehicle.

[0042] In this description, the ranges of values ​​include the bounds that delimit them.

[0043] In the present description, the equality between the values ​​is not to be understood in the strict sense insofar as each equality allows a variation of at most 10%, preferably at most 5%, more preferably at most 2%, between these values.

[0044] In this description, the terms "vertical" and "horizontal" are not to be understood in the strict sense of the term. Indeed, they allow an inclination of at most 20°, preferably at most 10°, more preferably at most 5°, even more preferably at most 2°; in relation to the strict meaning of these terms.

[0045] Throughout the description, the different figures use the same reference signs to designate identical or similar entities.

[0046] Figure 1 shows a diagram of a method for decorating a body panel of a motor vehicle, according to one embodiment of the invention. The motor vehicle includes energy storage means and at least one motor (not shown) adapted to power said motor vehicle. The motor vehicle includes a structure forming an outer body, or the main frame of the motor vehicle. The structure is formed from an assembly of stamped and welded sheet metal panels. The structure incorporates rotating, movable openings and front and rear bumper skins. The structure locally forms the body of the motor vehicle. Its precision and uniformity enhance the perceived quality.

[0047] The motor vehicle can, for example, be a private motor vehicle or a commercial motor vehicle.

[0048] The decoration process comprises the following steps, carried out in the following order:

[0049] a) supply or production 100 of the envelope part;

[0050] b) application 102 of a paint film on the envelope piece;

[0051] c) application 104 of a varnish film on the support surface of the envelope part;

[0052] d) printing 106 of a decorative layer by sublimation of ink against the support surface, said ink passing through the varnish film obtained following step c) application 104 of the varnish film;

[0053] e) application 108 of a second varnish film with a second thickness less than the first thickness; then optionally,

[0054] f) polishing 110 of varnish film.

[0055] Step a) supply or production 100 includes a cataphoresis substep. It may include cutting, stamping, or spot welding of sheet metal. Other assembly methods are considered.

[0056] Before step b) application 102 of the paint film, the decoration process includes cleaning the envelope part, in particular the support surface.

[0057] Due to the presence of the optional paint film applied during step b) application 102, step d) printing 106 reaches the paint film through the varnish film. The ink migrates through the varnish film. Step b) application 102 may include a substep for drying the paint film.

[0058] Following step c) application 104, the varnish film exhibits porosity with a network of pores traversing said varnish film. In step d) printing 106, said ink The varnish film passes through the aforementioned pore network. Following step d) printing 106, the decorative layer is within the thickness of the varnish film. It is encapsulated between the varnish film and the envelope piece.

[0059] The body panel is an exterior body part. Step c) application 104 includes applying varnish with a sprayer, preferably mounted on a robot. This varnish includes a hardener. The hardener limits scratches and abrasion. The varnish has a first density, and the ink has a second density greater than the first. This characteristic promotes ink migration. The densities are preferably measured in the liquid phase, before application to the body panel.

[0060] According to one embodiment, the envelope piece comprises an edge with two opposing faces and a ridge connecting the opposing faces. The edge forms a lip, or a rebate, between two sheets. In step d) printing 106, the decorative layer covers the ridge and the opposing faces. This optimizes the perceived quality.

[0061] According to one option of the invention, the envelope piece further comprises a rib. The rib forms a raised line, set back from the edges of the envelope piece. It may correspond to a style line. In step d) printing 106, the decorative layer covers said rib.

[0062] During step d) printing 106, an inflated bag exerts pressure against the envelope piece. Step d) printing 106 includes applying pressure of 100 g / m² to 200 g / m² to the envelope piece, directed from the decorative layer towards the envelope piece.

[0063] In printing step d) 106, the ink has a sublimation temperature. Printing step d) 106 is carried out at a temperature between 100% and 130% of said sublimation temperature. Preferably, printing step d) 106 has a temperature between 80°C and 120°C. The temperature increase is ensured by an additional heat source.

[0064] Prior to step d) printing 106, the decoration process includes a drying and degassing step of the varnish film. This step limits the blistering of the coating and the risk of corrosion. It contributes to the perceived quality.

[0065] The casing piece comprises metal, plastic, wood or ceramic. It may comprise a composite material with reinforcing fibers and a polymer resin.

[0066] This step d) printing 106 can be iterated. It is repeated in order to implement several decorative layers stacked one on top of the other. These stacked layers can be of equal thickness and / or the same color. This improves the rendering, thanks to decorative layers of lesser thickness. In step d) printing 106, the decorative layer includes several colors. This allows for the creation of polychrome patterns.

[0067] Step d) printing 106 comprises substep d1) supplying 112 a transfer sheet; substep d2) printing 114 a decoration on the transfer sheet; substep d3) applying 116 the transfer sheet to the envelope piece; substep d4) heating 118 the transfer sheet against the envelope piece; and substep d5) removing 120 the transfer sheet. The transfer sheet is also referred to as the medium or temporary support.

[0068] Generally, step c) application 104 of the varnish film is a first step of applying a first varnish film with a first thickness. Following step d) printing 106, the decoration process further includes a step e) application 108 of a second varnish film on top of the first varnish film. The second varnish film has a second thickness that is thinner than the first.

[0069] Step f) polishing 110 of the varnish film includes polishing the first varnish film, or the second varnish film as appropriate. Step f) polishing 110 is preferably automated using a robot to ensure homogeneity. Alternatively, it can be performed manually.

[0070] The body panel is an inner or outer body panel of the motor vehicle. It forms the outer skin of the motor vehicle, or the surface delimiting the interior of the vehicle, such as the passenger compartment.

[0071] Step d) printing 106 is optionally carried out under vacuum.

[0072] Figure 2 shows a motor vehicle body part during a step sublimation printing, according to an embodiment of the invention. The motor vehicle may correspond to the one shown in relation to [Fig. 1]. The wrap part and the printing step correspond to those shown in relation to [Fig. 1].

[0073] The outer casing 10 is the receiver for the decorative layer. It can be an interior panel within the passenger compartment, or an exterior panel representing the bodywork. It can form part of the structure of the motor vehicle. The outer casing 10 is a finishing part. It is a visible part, from the inside and / or outside of the vehicle. The outer casing 10 has a support surface 12. The support surface 12 is treated.

[0074] A varnish film 14 covers the outer casing 10, in particular the support surface 12. The varnish precursor material used is of the mono- or bi-component type, namely a resin and possibly a hardener which are mixed just before application and, for resins, consist of acrylic-melamine type polymers, polyesters, and hardeners of the type HDI (hexamethylene diisocyanate), IPDI (isophorone diisocyanate) or a mixture of both.

[0075] The varnish film 14 provides a glossy finish. It has a thickness of between 0.01 mm and 0.1 mm; preferably between 40 µm and 60 µm. This thickness is average. It is also referred to as the first layer. The thickness is preferably constant. The decorative layer 16 is thinner than the varnish film 14.

[0076] The decorative layer 16 is temporarily supported by a transfer sheet 18, or temporary backing sheet. The transfer sheet 18 receives the decorative layer 16, which is printed onto it before being applied to the envelope piece 10. The transfer sheet 18 conforms to the geometry of the support surface 12. The transfer sheet 18 is waterproof to control the sublimation of the ink from the decorative layer 16. It is stacked vertically on the envelope piece 10.

[0077] During the sublimation printing step, an inflatable bag 20 exerts pressure against the envelope piece 10. The pressure is maintained for a predetermined time. The inflatable bag 20 is advantageously inflated with a gas. The inflatable bag 20 forms a template for applying the transfer sheet. Its geometry is complementary to that of the envelope piece 10. The inflatable bag 20 reproduces the ribs and slanted edges of the envelope piece 10. It conforms to the shape of the envelope piece 10.

[0078] The inflated bag 20 allows for the application of homogeneous pressure. It exerts a pressure of 100 g / m2 to 200 g / m2 on the envelope piece 10, in particular on the support surface 12 through the varnish film 14, the decorative layer 16 and the transfer sheet 18. For example, the pressure is 150 g / m2.

[0079] Figure 3 shows a cross-section of the body panel 10 of a motor vehicle, according to an embodiment of the invention. The motor vehicle may correspond to the one shown in relation to one of Figures 1 to 2. The body panel 10 generally corresponds to that shown in Figure 2; however, it differs from it in that it comprises a paint film 22 under the varnish film 14.

[0080] The casing piece 10 comprises metal, wood or ceramic such as glass. The metal is steel or aluminum.

[0081] The wrap-around part 10 is an exterior bodywork element or an interior element of a motor vehicle. Preferably, the wrap-around part 10 is a bumper skin of a motor vehicle. Alternatively, the wrap-around part is a wooden decorative panel mounted on the dashboard or a side door trim, delimiting the passenger compartment.

[0082] Following sublimation printing, the decorative layer 16 is within the thickness of the varnish film 14. More precisely, the varnish film 14 comprises a stack of films.

[0083] The envelope part 10 is first coated with a first varnish film 24 in a first layer. This first varnish film 24 is an interlayer, or primer, varnish film. A second varnish film 26 has a second layer that is thinner than the first. This second varnish film 26 is an outer film, or finishing film. The decorative layer 16 is located within the first varnish film 24. It is separated from the second varnish film 26. The presence of the second varnish film 26 improves the finish, particularly after dye-sublimation printing. However, the second varnish film 26 remains optional.

[0084] The varnish film 14, the first varnish film 24, or the second varnish film 26 undergoes polishing. The polishing is carried out with a polishing tool 28. The polishing tool 28 comprises a felt pad that rubs against the varnish film 14 in order to reduce its roughness and thus improve its gloss.

[0085] According to one embodiment, the casing is made of a plastic or composite material. The plastic material may include a thermoplastic or thermosetting material. According to a preferred embodiment, the plastic material is selected from the group comprising polypropylene, polyamide, polyphthalamide, polyetheretherketone, polyphenylene sulfide, polyamide-imide, polyetherimide, polyarylamide, polyepoxide, unsaturated polyester, vinyl ester, or polyester-vinylester resins. For example, the composite material comprises a matrix of a plastic material as described above with reinforcement. For example, the reinforcement comprises glass or carbon fibers.

[0086] The body panel comprises at least 10% by weight of recycled plastic material based on the total weight of the plastic material; preferably from 10 to 80% by weight; more preferably from 20 to 60% by weight or from 30 to 40% by weight. The use of recycled plastic material reduces the vehicle's environmental footprint.

[0087] The invention comprises the combination of all the embodiments illustrated by all the figures.

Claims

Demands

1. A method for decorating a support surface (12) of a motor vehicle body part (10), the decoration method comprising the following steps: • a) supplying or producing (100) a body part (10); • d) printing (106) of a decorative layer (16) by ink sublimation against the support surface (12); characterized in that prior to step d) printing (106), the decoration method further comprises a step • c) application (104) of a varnish film (14) on the body part (10); at step d) printing (106) said ink passes through the varnish film (14) obtained following step c) application (104) of the varnish film (14).

2. A decoration method according to claim 1, characterized in that prior to step c) application (104) of the varnish film (14), the decoration method comprises a step b) application (102) of a paint film (22) on the envelope piece (10); step d) printing (106) by sublimation reaching the paint film (22) through the varnish film (14).

3. A decoration method according to any one of claims 1 to 2, characterized in that the envelope part (10) is an exterior bodywork part, step c) application (104) of the varnish film (14) comprises application by a sprayer, said varnish comprising a hardener; preferably, the varnish has a first density, the ink comprises a second density greater than the first density.

4. A decoration method according to any one of claims 1 to 3, characterized in that during step d) printing, an inflated bag (20) exerts pressure against the envelope piece (10); and / or step d) printing (106) comprises applying a pressure of 100 g / m2 to 200 g / m2 on the envelope piece (10).

5. A decoration method according to any one of claims 1 to 4, characterized in that in step d) printing (106), the ink comprises a sublimation temperature, step d) printing (106) being carried out at a temperature between 100% and 130% of said sublimation temperature; preferably, step d) printing (106) includes a temperature between 80°C and 120°.

6. A decoration method according to any one of claims 1 to 5, characterized in that the envelope piece (10) comprises an edge with two opposite faces, a slice connecting the opposite faces, at step d) printing (106), the decorative layer (16) covers the slice and the opposite faces; and / or the envelope piece (10) comprises a rib, at step d) printing (106), the decorative layer (16) covers said rib.

7. A decoration method according to any one of claims 1 to 6, characterized in that step c) application (104) of the varnish film (14) is a first step of applying a first varnish film (24) with a first thickness; following step d) printing (106), the decoration method further comprises a step e) application of a second varnish film (26) with a second thickness less than the first thickness.

8. A decoration method according to any one of claims 1 to 7, characterized in that step d) printing (106) comprises a substep d1) supplying (112) a transfer sheet (18); a substep d2) printing (114) of a decoration on the transfer sheet (18); a substep d3) application (116) of the transfer sheet (18) onto the envelope piece (10); a substep d4) heating (118) of the transfer sheet (18) against the envelope piece (10); a substep d5) removal (120) of the transfer sheet (18).

9. A decoration method according to any one of claims 1 to 8, characterized in that in step d) printing (106), the decorative layer (16) comprises several colors; and / or step d) printing (106) is repeated in order to implement several decorative layers stacked one on top of the other.

10. A decoration method according to any one of claims 1 to 9, characterized in that prior to step d) printing (106), the decoration method includes a step of drying and degassing the varnish film (14); preferably, the envelope piece (10) comprises metal, plastic, wood or ceramic.

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