Method for manufacturing a lighting component for a vehicle

Abstract

The present invention relates to a lighting component (1) for a vehicle, which has an outer surface on a visible side (6) and a multi-layer structure incorporating electronic components (7, 8), one of the layers (5) containing a metal, and a light-emitting diode (8) is arranged as a part of the electronic components (7, 8) on the side opposite the visible side (6) of the metal-containing layer (5). The present invention is characterized in that the surface of the metal-containing layer (5) facing the visible side (6) of this layer is partially covered with a colored layer (2), a portion (3) of the metal-containing layer (5) not covered with the colored layer (2) has a three-dimensional shape, and a light-emitting structure (9) is arranged in the region of the three-dimensional shape on the side opposite the visible side (6) of the metal-containing layer (5).

Description

[Technical field]

[0001] The invention relates to a method for manufacturing such a lighting component, and to a vehicle equipped with the component so manufactured. [Background technology]

[0002] Lighting components in the area of ​​vehicles, in particular in the outer panels of vehicles, are largely known from the prior art. For example, individual elements can be illuminated from the back, are completely or partially transparent and emit light in particular special patterns. This makes it possible, for example, to realize illuminated brand logos etc. in the area of ​​the radiator grille of a vehicle.

[0003] In practice, such components are relatively complex since they require an actual component with the desired optical form and an illumination unit assigned to the component. It is possible to use light guides, but this structure is still relatively thick from its surface acting as the visible side to the surface or back surface opposite this visible side. This has the major drawback, especially when this structure is used in the area of ​​the outer panels, that the installation space here is rather limited in many areas, depending on the desired design.

[0004] To solve this problem, it is now possible to choose very compact structures. From US Pat. No. 5,399,433 it is known, for example, to introduce light-emitting diodes into a two-dimensional, multi-component injection-molded structure. The multi-layer construction of this injection-molded structure can then contain various layers of various materials, such as natural materials or metals. According to the aforementioned US patent, it is also conceivable in principle to provide the outer surface, i.e. the front surface, which closes the structure, with a metal coating, for example a chromium coating.

[0005] Patent document 2 also describes a comparable structure for a multi-component injection molding process in which light-emitting diodes are introduced. In that case, the intermediate film can contain various decorations and colors. A deep drawing process is then used to form a bulge for the light-emitting diode, which is then covered from the visible side with a transparent cover layer.

[0006] US Patent No. 5,399,633 describes a decorative vehicle part with a luminescent finish, where the surface is mounted on a light guide and provided with a metal top layer, allowing light to be emitted from individual apertures.

[0007] US Patent No. 5,399,633 describes an embodiment of a light-emitting structure made of several film layers, molded in three dimensions with recesses for light-emitting elements, on which a back-illuminated surface can be placed.

[0008] Patent document 5 describes a light assembly including two rear lights of a vehicle and an illuminated decorative strip arranged between them, in which a cover glass is covered with a translucent chrome film that allows the lights to glow when they are turned on. Furthermore, a method for producing flat trim elements for vehicles is known from DE 199 10 200 43 597. This comprises a light-transmitting laminate having recesses or depressions covered with a transparent plastic, the recesses forming a raised decorative pattern on the visible side. This structure can be illuminated by a light source. [Prior art documents] [Patent documents]

[0009] [Patent Document 1] US10,485,094B1 [Patent Document 2] US2018 / 0149321A1 [Patent Document 3] WO2020 / 168324A2 [Patent Document 4] US20180149321A1 [Patent Document 5] US2018 / 0264991A1 [Patent Document 6] DE102020005896A1 Summary of the Invention [Problem to be solved by the invention]

[0010] It is therefore an object of the present invention to provide an improved manufacturing method for lighting components which allows for simple and efficient implementation of further design aspects, in particular in space-saving components suitable for the outer panels of vehicles. [Means for solving the problem]

[0011] According to the invention, the above problem is solved by a method for manufacturing a lighting component having the features of claim 1, and here in particular the features recited in the characterizing part of claim 1. Advantageous embodiments and developments of the invention emerge from the dependent subclaims. In claim 6, a vehicle with a component thus manufactured is described, which likewise solves the above problem.

[0012] The lighting components for vehicles to be manufactured include a multi-layer structure incorporating electronic components, which include, among others, light-emitting diodes as part of these electronic components. In that case, one of the layers includes metal and can be formed, for example, as a metal layer or as a metallized plastic layer. Metal can be vapor-deposited on the plastic layer, for example. The lighting components have an outer surface, hereinafter also called the front surface, on the visible side.

[0013] In that case, the metal-containing layer has electronic components arranged on the side opposite to the visible side. In that case, the metal-containing layer is partially or locally covered with a colored layer on the surface facing its visible side, and the parts of the metal-containing layer that are not covered by the colored layer have a three-dimensional shape, i.e. these parts are deformed from the plane of the metal-containing layer, for example, but not necessarily, in the direction of the visible side. In that case, the metal-containing layer itself does not have to be in a geometric plane, but can quite also be curved, the three-dimensional shape protruding above or receding below the surface of this layer to achieve the desired effect.

[0014] In that case, light-exiting structures are further arranged in the region of these three-dimensionally formed parts of the metal-containing layer on the side opposite to the visible side or on the surface of the metal-containing layer. Such light-exiting structures can be introduced into the metal-containing layer, for example, by printing or embossing. The light-exiting structures cause the light of the light-emitting diodes behind the metal-containing layer, in particular behind the colored layer locally covering the visible side of this layer, to exit through the light-exiting structures in the regions where the colored layer is interrupted. This allows for a structure that allows for a very high design flexibility by minimizing the structural thickness transverse to the stacking direction of the individual layers, so that, for example, individual parts are left uncovered when the colored layer is properly placed, and these parts are illuminated from the back when the light-emitting diodes are switched on, while making the metal-containing layer visible. This allows, for example, design parts, letters, symbols, etc. to be displayed very effectively, which can be used in particular for displaying brand logos, model names, etc.

[0015] The method according to the invention for producing such lighting components then provides for six basic steps, which are described below, for producing lighting components. In a first step, the metal-containing layer, i.e. in particular a chrome film, is locally provided on the future visible side with a colored layer, which can be done in particular by printing, for example by screen printing. Then, in a second step, the metal-containing layer is provided on its back side opposite the future visible side with at least parts of electronic components, such as conductor tracks. Furthermore, in this step, the metal-containing layer on the opposite front side is provided with light-emitting structures in the areas not provided with a colored layer, i.e. not covered with a colored layer. All this can be done in a manner known per se, in particular by screen printing or, in the case of light-emitting structures, by embossing, for example.

[0016] In the next step, electronic components are then applied, which can be realized by one or more printed layers. This applies in particular to light-emitting diodes, whereas other electronic components such as resistors or capacitors can be produced together with conductor tracks, often by printing on the back side of the metal-containing layer. This step is then followed in a fourth step by the three-dimensional shaping of the areas not provided with a colored layer, in that these areas are correspondingly shaped by deep drawing or thermoforming and are deformed, for example as a three-dimensional structure, beyond the colored layer in the direction of the future visible side. In particular, when embossing the light-emitting structure, unlike the printing of the light-emitting structure by screen printing, the introduction of the light-emitting structure can also be carried out for the first time in this deep-drawing step, in particular when the deep-drawing step is carried out by a suitable tool that embosses the light-emitting structure on the metal-containing layer, which can be formed, in particular, as a chrome film, on the side opposite the future visible side.

[0017] In a next step, a support layer is then attached to the back side of the metal-containing layer, which stabilizes the previous structure, supports the three-dimensionally shaped area and ensures that the electronic components are enclosed, for example by back injection molding as already mentioned above, or by attaching another film and injecting the material of the support layer between the film and the metal-containing layer.

[0018] Finally, in a sixth step, a transparent plastic is applied as a cover layer on the visible side, which, as already mentioned above, can preferably be made smooth, i.e. the previously three-dimensional design on the visible side can again have a smooth surface under which the three-dimensionality acts on the underlying layers, so that these can be seen, but without protrusions that are tactilely perceptible and / or that risk accumulating dirt.

[0019] In a very advantageous development of the method according to the invention, it can be provided that, as already mentioned, the application of the transparent cover layer is carried out by flooding or injection coating of a transparent plastic, in particular by flooding of polyurethane. In a very advantageous development of the method according to the invention, the light-exiting structure can then be introduced into the metal-containing layer in step 2 by a printing method, in particular a screen printing method, and / or in step 4 by embossing, also as already mentioned.

[0020] In a very advantageous development of the method according to the invention, it is provided that the metal-containing layer is formed as a chrome film. So-called chrome films are typically plastic films that are provided with, in particular vapor-deposited with, for example, chrome, silver or similar materials to give them a metallic appearance. This makes it possible to obtain a metallic-acting film with a relatively low metal content, whereby the film transmits light in at least one direction and in particular reflects light in another direction. Furthermore, due to the low metal content of the corresponding layer, it can be made almost transparent to radar radiation, so that, for example, a corresponding radar sensor, such as is used in the surrounding sensor system of a vehicle, can be arranged behind the lighting component without affecting its function.

[0021] In a further very advantageous embodiment of the method, it can furthermore be provided that the colored layer is formed as an opaque colored layer. Such an opaque colored layer does not transmit light, so that in the case of lighting using light-emitting diodes, the light is only emitted in the area of ​​the light-emitting structures and shines through the metal-containing layer, whereas the adjacent areas covered by the colored layer do not transmit light. In a preferred use of the lighting component in the area of ​​the exterior panel of the vehicle, it can be provided that the colored layer is formed in the same color as the paint of the vehicle or in a color that matches the design, for example a contrasting color.

[0022] A vehicle according to the invention comprises a part manufactured according to this method.

[0023] Further advantageous embodiments of the lighting component according to the invention will become apparent from the exemplary embodiments which are explained in more detail below with reference to the drawings. [Brief description of the drawings]

[0024] [Figure 1] FIG. 1 is a basic schematic front view of a possible lighting component. [Diagram 2] FIG. 2 is a cross-sectional view of a portion of the lighting component. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0025] In the illustration of FIG. 1, one can recognize a lighting component, generally designated 1, which can be installed, for example, in the area of ​​the outer panel of the vehicle. This is, for example, a part called a radiator grille at the front of the vehicle in a conventional vehicle with an internal combustion engine, which part, for example, in an electrically driven vehicle, may no longer be in the form of an air-permeable grille, but may be formed in the form of a closed part. The component 1 itself is then locally formed in the color of the vehicle and has several parts, designated 3, here shown in the form of four rectangles and one circle, which are not formed in the color of the vehicle and appear with a metallic, for example chrome, appearance when the rear lighting is switched off.

[0026] As can be seen on the basis of the illustration in FIG. 2, these parts are formed three-dimensionally and face towards the viewer in the transparent cover layer 4, so that the appearance of, for example, a generally known chrome-plated brand logo, such as the well-known star of the applicant, arises. To achieve this, a structure is formed as shown in the cross-section in FIG. 2. In this case, emphasis is laid in particular on a simple and compact structure which is formed very thin, but which nevertheless allows to achieve three-dimensional optical effects. For this, as a central component, a chrome film 5 is provided as a metal-containing layer. On the side of this layer which faces towards the visible side 6 shown above in the illustration in FIG. 2, the already mentioned color layer 2 is provided, which may in particular be a color layer of the color of the car. If this color layer 2 is applied locally to the chrome film 5, the parts shown in the illustration in FIG. 1 with 3 are not covered. These parts then form a three-dimensional structure later in the direction of the visible side 6, or essentially also in the direction opposite to the direction of the visible side 6, as can be seen in the illustration in FIG. 2.

[0027] Initially, the composite of the chrome film 5 produced in this first step and the color layer 2 placed locally on this chrome film 5 is still flat. This composite is then provided with electronic components which are printed at least partially. In this case, purely by way of example, printed conductor tracks 7 are visible in the illustration in FIG. 2, in the region of these conductor tracks two light-emitting diodes 8 are attached. In the region 3, light-emitting structures 9 are likewise provided, also by printing, on the side opposite the visible side 6 of the chrome film 5, so that these light-emitting structures are not visible from the visible side 6 in the non-illuminated state. This composite of the electronic components 7, 8, the chrome film 5 and the color layer 2, which are provided with the light-emitting structures 9 in the corresponding part 3, is then subjected to a deep-drawing process or a thermoforming process in order to generate the three-dimensional form already visible in FIG. 2. This creates here two facets in the part 3, which are visible from the visible side 6. After this three-dimensional shaping process, a support layer 10, as shown in Fig. 2, is then applied, for example by back-injection molding the support layer 10 on the back side of the previous structure. In that case, the support layer 10 is formed as a transparent or translucent thermoplastic, which can be back-injection molded, in particular in the region of the three-dimensionally deformed region 3 with the printed conductor tracks 7, the LEDs 8 and the light-exiting structures 9.

[0028] Finally, this structure is then sealed with the already mentioned cover layer 4, which can likewise be formed as a transparent thermoplastic or in particular as a cast layer of polyurethane. The component, i.e. this cover layer 4, is for example injection-coated or preferably flood-coated, so that the layer thickness of the cover layer 4 is greater than the three-dimensional shape of the part 3. This results in a smooth surface on the visible side 6, beneath which the three-dimensional shape of the part 3, i.e. here the facet structure, is correspondingly recognizable, but does not protrude beyond the surface of the visible side 6.

[0029] In the non-illuminated state, the structure then has an optical impression from the combination of the chrome of the chrome film 5 in the part 3 and the car color in the colored layer 2 applied thereon. When the light-emitting diodes 8 are switched on, the transparent or translucent support layer 10 is illuminated, thereby lighting the lighted part 2 from the back. However, the colored layer 2 is ideally not light-transmitting, so that only in the area of ​​the part 3 is the light-emitting structure 9 assisted or enabled to emit light in the direction of the visible side 6. That is to say, in this case, the impression of a lighted part 3, for example a lighted brand logo, is created on a part painted in the car color. The light-emitting diodes 8 can then be realized and controlled in any way, whereby in particular different colors, changing colors, etc., as well as flashing, for example regulating the light intensity depending on the ambient brightness, increasing and decreasing the light intensity, etc. are also conceivable.

[0030] In that case, the entire component 1 can be made extremely compact transversely to the stacking direction of the individual layers and can therefore, so to speak, be integrated into any existing design without any problems and can also be integrated easily and efficiently into existing designs without the need for a design adaptation to balance or the available installation space, as opposed to previous structures which use more complex and therefore thicker lighting technology.

Claims

1. A method for manufacturing a lighting component (1) for a vehicle, the lighting component (1) having an outer surface on a visible side (6) and a multi-layer structure incorporating electronic components (7, 8), one of layers (5) containing a metal, the metal-containing layer (5) having a surface facing the visible side (6) of the layer partially covered with a colored layer (2), a light-emitting diode (8) is arranged as part of the electronic component (7, 8) on the side opposite the visible side (6) of the metal-containing layer (5) covered with the colored layer (2), a portion (3) of the metal-containing layer (5) not covered with the colored layer (2) has a three-dimensional shape, and a light-emitting structure (9) is arranged in the region of the three-dimensional shape on the side opposite the visible side (6) of the metal-containing layer (5); To this end, in a first step, the film (5) forming the layer (5) containing the metal is locally provided with the colored layer (2) on its front side facing the later visible side (6), In a second step, the film (5) is provided with at least a part of the electronic components (7, 8) and the light output structure (9) on a back surface facing away from the later visible side (6), In the third step, other electronic components including the light emitting diode (8) are mounted. In a fourth step, the portion (3) of the film (5) on which the colored layer (2) is not provided is formed into a three-dimensional shape by deep drawing or thermal deformation, In a fifth step, a transparent or translucent support layer (10) is attached to the back side of the film (5), which is illuminated when the light-emitting diodes (8) are switched on; In a sixth step, a transparent plastic is provided as a cover layer (4) on the visible side (6) of the film (5).

2. 2. A method according to claim 1, characterized in that the transparent cover layer (4) is applied by flood coating or injection coating of a transparent plastic.

3. 3. The method according to claim 1 or 2, characterized in that the light-exiting structures (9) are introduced into the film (5) by printing in the second step and / or by embossing in the fourth step.

4. 3. The method according to claim 1 or 2, characterized in that as the layer (5) containing metal a chromium film (5) is used.

5. 3. The method according to claim 1 or 2, characterized in that the coloured layer (2) is formed as an opaque coloured layer (2).

6. A vehicle equipped with a lighting component (1) manufactured according to claim 1 or 2.

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