Method for manufacturing a component, in particular a panel, for a motor vehicle

Abstract

The present invention relates to a method for manufacturing an automotive component (1), comprising four steps a) to d). In the first step a), a substrate (2) is provided, made of a metallic substrate material, having a front surface (3) serving as a viewing surface, a back surface (4) facing the front surface (3), and a predetermined substrate thickness (d). In the second step b), the substrate material is stripped from at least the front surface (3) of the substrate (2), preferably from both the front surface (3) and the back surface (4), in at least one first substrate region area (6a) by an etching process, thereby forming at least one opening (5) in the substrate (2) after stripping, extending from the front surface (3) to the back surface (4). Furthermore, after stripping, the substrate thickness (d) is reduced in at least one first substrate region (6a) of the substrate (2) compared to at least one second substrate region (6b) from which the substrate material has not been stripped. In a third step c), the front surface of the substrate (2) is coated with a color layer (8), the color of which is different from the color of the front surface (3) of the substrate (2) before being coated with the color layer (8), and then at least the color layer is removed from at least one second substrate area (6b). In a fourth step d), a photoactive member (10) is attached to at least a partial area of ​​the back surface (4) of the substrate, whereby the photoactive member (10) covers at least one opening (5).

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing a component, in particular a panel, for a motor vehicle, and to the component manufactured by this method. [Background technology]

[0002] Illuminated metal panels offer a visually appealing design to the observer and have versatile uses in the interior spaces of modern automobiles.

[0003] In this context, conventional manufacturing methods are known for producing such panels, in which the material of the panel has a different color than the light emitted from the panel, i.e., two-color panels can be produced by such methods. Summary of the Invention [Problem to be solved by the invention]

[0004] The object of the present invention is to provide a novel method for producing illuminated panels. In particular, it is intended to provide a manufacturing method that is as simple as possible, which allows for the production of illuminated panels in three colors. By "three colors" it is understood that the surface of the panel visible to the observer is made up of two colors, both of which are different from the color of the light emitted from the panel. [Means for solving the problem]

[0005] The above problem is solved by the subject matter of the independent claims. Preferred embodiments are the subject matter of the dependent claims.

[0006] Accordingly, the basic idea of ​​the present invention is to process a metal substrate by a combination of an etching process, coating with a color layer, and partially removing the color layer, preferably by grinding. This allows a two-color surface, which serves as the viewing surface of the panel, to be realized at relatively low technical cost. During the etching process, openings are created in the metal substrate, which can be filled with a transparent, i.e., light-transmitting, material or a photoactive, i.e., actively emitting, material. The photoactive element is a light source, and can in particular include a light-emitting diode (LED). In particular, suitable light-transmitting plastics can be used as photoactive or phototransmitting materials, since they can be processed particularly easily during the method of the present invention.

[0007] In this way, light can be emitted from these openings having a color different from both of the colors of the substrate surface, thus resulting in the manufacture of components or panels having a viewing surface with any desired three colors.

[0008] In particular, the method according to the invention for producing a component, in particular a panel, for the interior space of an automobile vehicle comprises four steps a) to d). In the first step a), a substrate is provided, which is made of a metallic substrate material and has a front surface serving as a viewing surface, a back surface opposite the front surface, and a predetermined substrate thickness. In particular, the substrate may be made of a metal plate, preferably made of special steel.

[0009] According to the second step b), the substrate material is stripped from at least the front surface of the substrate, preferably from both the front surface and the back surface, in the region of at least one first substrate region, particularly preferably by an etching process, so that after stripping, at least one opening extending from the front surface to the back surface is formed in the substrate, and further, after stripping, the substrate thickness is reduced in the at least one first substrate region of the substrate compared to at least one second substrate region from which the substrate material has not been stripped. Thus, the first substrate thickness of the substrate in the region of the at least one first substrate region is smaller than the second substrate thickness in the region of the at least one second substrate region. The transition from the first substrate region to the second substrate region may be embodied by a step formed on the front surface.

[0010] In a third step c), the front surface of the substrate is in particular surface-coated with a color layer, the color of which is different from the color of the front surface of the substrate before being coated with the color layer.

[0011] In a fourth step d), a photoactive member is attached to at least a partial area of ​​the rear surface of the substrate, whereby the photoactive member covers the at least one opening.

[0012] According to a preferred development of the method according to the invention described above, the method comprises an optional step e) following step d), in which a decorative coating is applied to the front surface of the substrate, in the region of the first substrate area processed by the stripping of the substrate material in step b). In this way, the visual impression provided to the observer by the component can be further improved.

[0013] It is particularly advantageous that the decorative coating can be applied by the PVD method. The PVF method allows the above-mentioned decorative coating to be applied particularly easily to the substrate, and ensures a permanently secure adhesion of the decorative layer on the substrate.

[0014] In a preferred development of the method according to the invention, before the application of the photoactive component according to step d), the substrate can be shaped, in particular bent, in an additional step z), in order to give the substrate a desired geometric shape.

[0015] In another preferred development of the method according to the invention, it is also possible to introduce a photoactive member into at least one opening covered by the photoactive member in step d), in which case light is emitted directly from the opening, which further improves the visual impression of the component for the observer.

[0016] In another preferred development of the method according to the invention, an optically transparent member can be introduced into at least one opening covered by the optically active member in step d) in an additional step y) before carrying out step d), so that light generated by the optically active member attached to the back side of the substrate in step d) can pass through the optically transparent member and exit from the opening on the front side of the substrate.

[0017] The light-transmitting member is particularly advantageously made of or includes a plastic material which is preferably introduced into the opening by injection moulding, casting or painting.

[0018] It is particularly preferred that the photoactive or light-transmitting member can be introduced into at least one opening such that after introduction the photoactive or light-transmitting member protrudes from the opening at the front surface of the substrate.

[0019] It is particularly advantageous for the photoactive member to consist of or include a plastic material, which is attached to the back surface of the substrate, preferably by gluing, casting or back-injection molding, or introduced into at least one opening.

[0020] Furthermore, the present invention relates to a component for a motor vehicle, comprising at least one component or panel manufactured by the inventive method proposed above.

[0021] Further important features and advantages of the invention emerge from the dependent claims, the drawings and the corresponding description based on the drawings.

[0022] It is to be understood that the features mentioned above, and those further described below, may not only be used in the combinations shown, but may also be used in other combinations or alone, without departing from the scope of the invention.

[0023] DETAILED DESCRIPTION OF THE INVENTION Preferred embodiments of the present invention are illustrated in the drawings and described in more detail below, where like reference numbers indicate identical or similar or functionally identical components.

[0024] Here, the following is generally described in each of the drawings: [Brief explanation of the drawings]

[0025] [Figure 1] 1 is a process diagram illustrating, by way of example, a method according to the invention; [Figure 2a] 1 is a component manufactured by the method according to the invention. [Figure 2b] 1 is a component manufactured by the method according to the invention. DETAILED DESCRIPTION OF THE INVENTION

[0026] FIG. 1 shows a flow diagram illustrating the method of the invention for manufacturing a component 1 according to the invention.

[0027] In step a) of the method, a substrate 2 is provided, which is made of a substrate material and further has a front surface 3 that serves as a viewing surface, a back surface 4 opposite the front surface 3, and a predetermined substrate thickness d.

[0028] In the next step b), substrate material is removed by an etching process in the region of first substrate regions 6a (only one such first substrate region 6a is shown in FIG. 1 ) on at least the front surface 3 of the substrate 2, preferably both the front surface 3 and the back surface 4. This removal is performed in such a way that openings 5 ​​(two such openings 5 ​​are shown in FIG. 1 by way of example) are formed in the substrate 2 after the removal, each extending from the front surface 3 to the back surface 4. Due to the removal, the substrate thickness of the substrate 2 in the first substrate region 6a is reduced compared to the second substrate region 6b, from which the substrate material has not been removed. That is, the first substrate thickness d1 of the substrate 2 in the region of the first substrate region 6a is smaller than the second substrate thickness d2 of the substrate 2 in the region of the second substrate region 6b. The transition from the first substrate region 6a to the second substrate region 6b can be embodied by a step 7 formed in the front surface 3.

[0029] In the next step c) of the method according to the invention, the front surface 3 of the substrate 2 is coated with a color layer 8 in a planar manner, the color of which differs from the color of the front surface 3 of the substrate 2 before being coated with the color layer 8. During step c), the color layer 8 is removed from all second substrate areas 6b by grinding or laser ablation, so that the second substrate areas 6b have a surface 16 free of the color layer 8 after grinding or laser processing.

[0030] As can be seen in FIG. 1, in an optional additional step y), a light-transmitting element 11 made of plastic material can be introduced into one of both openings 5 ​​.

[0031] In another optional additional step z), the substrate 2 can be bent as suggested in FIG.

[0032] In the next essential step d) of the method according to the invention, a photoactive element 10 is then applied to the rear surface 4 of the substrate 2, so that this photoactive element 10 covers both of the openings 5 ​​shown. At this point, the photoactive element 10 can also be introduced into the openings 5 ​​where no light-transmitting plastic has been introduced.

[0033] In this way, light generated by a light active member 10 attached to the back surface 4 can pass through a light-transmitting member 11 arranged in one of the openings 5 ​​and exit from said opening 5 at the front surface 4. Similarly, a light active member 10 arranged in the other opening 5 can generate light that also exits from an opening at the front surface 4 of the substrate 2. After performing step d), the component 1 according to the invention is completed.

[0034] Optionally, in a separate step e), not shown in the drawing, a decorative coating can be applied to the area of ​​the first substrate section 6a. The application of the decorative layer can be carried out by a PVD method.

[0035] Figures 2a and 2b show in schematic form an example of the configuration of a component 1 according to the invention in the form of a panel. Figure 2a shows a plan view and Figure 2b a cross-sectional view. In the example of Figure 1, the component 1 is part of a so-called "cup holder" 20 for receiving a beverage container (not shown), such as a coffee cup. As shown in Figures 2a and 2b, on the front face 3, which acts as the viewing surface, the light active member 10, the ground surface 16 and the color layer 8 can be seen.

Claims

1. A method for manufacturing a component (1), in particular a panel, for an automobile, comprising the following steps: a) providing a substrate (2) made of a metallic substrate material, said substrate (2) having a front surface (3) serving as a viewing surface, a back surface (4) facing said front surface (3), and a predetermined substrate thickness (d); b) the substrate material is stripped from at least the front surface (3) of the substrate (2), preferably from both the front surface (3) and the back surface (4), in the region of at least one first substrate region (6a) by an etching process, wherein after the stripping at least one opening (5) is formed extending from the front surface (3) to the back surface (4), and further wherein after the stripping the substrate (2) has a reduced substrate thickness (d) in the at least one first substrate region (6a) compared to at least one second substrate region (6b) where the substrate material has not been stripped; c) providing a surface coating of a color layer (8) on the front surface of the substrate (2), the color of the surface coating being different from the color of the front surface (3) of the substrate (2) before being coated with the color layer (8), and removing the color layer (8) from at least one of the second substrate areas (6b), preferably by grinding; d) attaching a photoactive member (10) to at least a partial area of ​​the back surface (4) of the substrate (2), whereby the photoactive member (10) covers at least one opening (5); The method comprising:

2. The method further comprises the following optional step e) following step d): e) a decorative coating (13) is applied to the front surface of the substrate (2) in the area of ​​the first substrate section (6a); 2. The method of claim 1, comprising:

3. 3. A method according to claim 1 or 2, characterized in that the decorative coating (13) is applied by a PVD method.

4. 4. The method according to claim 1, wherein the substrate (2) is shaped, in particular bent, in an additional step z) before the application of the light active component (10) according to step d) or c).

5. 5. The method according to claim 1, further comprising introducing the photoactive member (10) into at least one opening (5) covered by the photoactive member (10) in step d).

6. 6. The method according to claim 1, wherein an optically transparent member (11) is introduced into at least one opening (5) covered by the optically active member (10) in step d) in an additional step y) before performing step d), so that light generated by the optically active member (10) attached to the back surface (4) in step d) can pass through the optically transparent member (11) and exit from the opening (5) on the front surface (3) of the substrate (2).

7. 7. A method according to claim 6, characterized in that the light-transmitting element (11) consists of or comprises a plastic material which is preferably introduced into the opening (5) by injection moulding, casting or painting.

8. 8. The method according to claim 1, wherein the optically active member (10) or the optically transparent member (11) is introduced into at least one opening (5), and the optically active member (10) or the optically transparent member (11) protrudes from the opening (5) on the front surface (3) of the substrate (2) after the introduction.

9. 9. The method according to claim 8, characterized in that the light active member (10) consists of or comprises a plastic material and is attached to the back side (4) of the substrate (2) or introduced into at least one opening (5), preferably by gluing, casting or back-injection molding.

10. 10. A component for a motor vehicle, comprising at least one component (1) manufactured by a method according to any one of claims 1 to 9.

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