SELECTIVELY ILLUMINABLE METAL LOOKING TRIM AND METHODS FOR MANUFACTURING SAME - Patent application

Abstract

To provide an improved technique for selectively illuminable metallic-looking trim and methods for manufacturing the same. [Solution] A metallic-look trim for an object includes a transparent or translucent substrate defining a top and a bottom surface; an opaque layer applied to one of the top and bottom surfaces of the substrate and defining one or more openings through which light can pass; and one or more translucent metallic effect layers applied to the top surface of the opaque layer if the opaque layer is applied to the top surface of the substrate, or to the top surface of the substrate if the opaque layer is applied to the bottom surface of the object. The one or more metallic effect layers include one or more metallic effect paints or one or more layers of digitally printed metallic material. A light source is positioned below the bottom surface of the substrate and generates light that passes through the substrate, the one or more openings, and the one or more metallic effect layers.

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This application is a PCT International application claiming the benefit of Spanish Patent Application No. P201730785, filed June 9, 2017, and Spanish Patent Application No. P201830556, filed June 7, 2018. The disclosures of the above applications are incorporated herein by reference in their entirety.

[0002] FIELD OF THEINVENTION FIELD OF THE DISCLOSURE This application relates generally to decorative trim, and more specifically to selectively illuminable metallic looking trim and methods for their manufacture. [Background technology]

[0003] Decorative trim is applied to accentuate or enhance the visual appearance of an object. For example, interior and exterior components of vehicles often have decorative trim. To further enhance the visual appearance, light sources can be incorporated into the decorative trim to provide lighting effects. Chrome plating is one example of decorative trim that is often utilized due to its high gloss appearance. However, chrome plating can have negative environmental impacts, for example, due to the use of hexavalent chromium baths. Chrome plating also cannot be used in conjunction with backlight lighting effects because it is formed from one or more opaque metal layers that do not allow light to pass through. Thus, while such decorative trim works well for their intended purposes, improvements in the related technology are still needed. Summary of the Invention

[0004] According to one aspect of the present disclosure, a trim for an object is presented. In one exemplary embodiment, the trim comprises a transparent or translucent substrate defining a top surface, an opaque layer applied to the top surface of the substrate, the opaque layer defining one or more openings through which light can pass, and one or more translucent metallic effect layers applied to the top surface of the opaque layer.

[0005] In some embodiments, the one or more metal effect layers comprise one or more layers of metal effect paint, while in other embodiments, the one or more metal effect layers comprise one or more layers of digitally printed metal effect material.

[0006] In some embodiments, the one or more metal effect layers comprise only one or more basecoat layers of metal effect paint. In other embodiments, the one or more metal effect layers comprise (i) a semi-transparent primer layer applied on top of the opaque layer and to portions of the substrate corresponding to the one or more openings, and (ii) one or more semi-transparent basecoat paint layers applied on top of the primer layer. In some embodiments, the one or more metal effect layers further comprise a transparent or semi-transparent topcoat layer applied on top of the one or more basecoat paint layers, the topcoat layer protecting and enhancing the metallic effect of the one or more metal effect layers.

[0007] In some embodiments, at least one of the primer layer and the topcoat layer includes metal particles to further enhance the metallic effect of the one or more metallic effect layers, in some embodiments, the topcoat layer is lightly and / or darkly pigmented to further enhance the metallic effect of the at least one metallic effect layer.

[0008] In some embodiments, the trim is a selectively illuminatable trim further comprising a light source disposed beneath a bottom surface of the substrate and configured to output light through the substrate, the one or more openings defined by the opaque layer, and the one or more metallic effect layers, In some embodiments, the trim further comprises a light guide disposed between the light source and the bottom surface of the substrate and configured to distribute light output from the light source.

[0009] According to another aspect of the present disclosure, a trim for an object is presented. In one exemplary embodiment, the trim comprises a transparent or translucent substrate defining a top surface and a bottom surface, an opaque layer applied to the bottom surface of the substrate, the opaque layer defining one or more openings through which light can pass, and one or more translucent metallic effect layers applied to a top surface of the substrate.

[0010] In some embodiments, the one or more metal effect layers comprise one or more layers of metal effect paint, while in other embodiments, the one or more metal effect layers comprise one or more layers of digitally printed metal effect material.

[0011] In some embodiments, the one or more metal effect layers comprise only one or more basecoat layers of metal effect paint. In other embodiments, the one or more metal effect layers comprise (i) a semi-transparent primer layer applied on top of the substrate, and (ii) one or more semi-transparent basecoat layers of metal effect paint applied on top of the primer layer. In some embodiments, the one or more metal effect layers further comprise a transparent or semi-transparent topcoat layer applied on top of the one or more basecoat layers, the topcoat layer protecting and enhancing the metallic effect of the one or more metal effect layers.

[0012] In some embodiments, at least one of the primer layer and the topcoat layer includes metal particles to further enhance the metallic effect of the one or more metallic effect layers, in some embodiments, the topcoat layer is lightly and / or darkly pigmented to further enhance the metallic effect of the one or more metallic effect layers.

[0013] In some embodiments, the trim is a selectively illuminable trim further comprising a light source disposed beneath a bottom surface of the substrate and configured to output light through one or more openings defined by the opaque layer, the substrate, and the one or more metal effect layers, In some embodiments, the trim further comprises (i) the light source and (ii) a light guide disposed between the bottom surface of the substrate and the opaque layer and configured to distribute light output from the light source.

[0014] According to another aspect of the present disclosure, a method of manufacturing a trim for an object is presented. In one implementation, the method includes providing a transparent or translucent substrate defining a top surface and a bottom surface, applying an opaque layer to one of the top surface of the substrate and the bottom surface of the substrate, the opaque layer defining one or more openings through which light can pass, and applying one or more translucent metallic effect layers (i) to the top surface of the opaque layer if the opaque layer is applied to the top surface of the substrate, or (ii) to the top surface of the substrate if the opaque layer is applied to the bottom surface of the substrate.

[0015] In some embodiments, applying the one or more metal effect layers comprises applying one or more layers of metal effect paint. In other embodiments, applying the one or more metal effect layers comprises digitally printing one or more layers of metal effect material. In some embodiments, the one or more metal effect layers comprise only one or more primer layers of metal effect paint.

[0016] In some embodiments, applying the one or more metal effect layers comprises (i) applying a semi-transparent primer layer on top of the opaque layer and on portions of the substrate corresponding to the one or more openings, and (ii) applying one or more semi-transparent undercoat layers of metal effect paint applied on top of the primer layer. In some embodiments, the method further comprises applying a transparent or semi-transparent overcoat layer on top of the one or more undercoat layers, where the overcoat layer protects and enhances the metallic effect of the one or more metal effect layers.

[0017] In some embodiments, applying the opaque layer further comprises applying an initial opaque layer that does not define the one or more openings and removing portions of the initial opaque layer corresponding to the one or more openings to obtain the opaque layer. In some embodiments, applying the initial opaque layer comprises spraying an opaque primer and curing the sprayed opaque primer to obtain the initial opaque layer, and removing portions of the initial opaque layer comprises laser etching the initial opaque layer.

[0018] In some embodiments, applying the opaque layer further comprises applying a temporary mask layer to one of the top and bottom surfaces of the substrate, applying an initial opaque layer by spraying an opaque primer onto one of the top and bottom surfaces of the substrate and the temporary mask layer, and removing the temporary mask layer and portions of the initial opaque layer associated with the temporary mask layer to obtain the opaque layer. In other embodiments, applying the opaque layer comprises digitally printing an opaque material onto portions of the top surface of the substrate.

[0019] In some embodiments, the method further includes injection or compression molding, thermoforming, or additively manufacturing a plastic material to form the substrate. In some embodiments, the trim is a selectively illuminatable trim, and the method further includes disposing a light source beneath a bottom surface of the substrate, the light source configured to output light through the substrate, the one or more openings defined by the opaque layer, and the one or more metallic effect layers, and packaging the light source and the selectively illuminatable trim into a single integrated module.

[0020] According to another aspect of the present disclosure, a method of manufacturing a trim for an object is presented. In one exemplary embodiment, the method includes providing a transparent or translucent substrate defining a top surface, applying an opaque layer to the top surface of the substrate, the opaque layer defining one or more openings through which light can pass, and applying one or more translucent metallic effect layers to the top surface of the opaque layer.

[0021] In some embodiments, applying the one or more metal effect layers comprises applying one or more layers of metal effect paint, while in other embodiments, applying the one or more metal effect layers comprises digitally printing one or more layers of metal effect material.

[0022] In some embodiments, the one or more metal effect layers comprise only one or more basecoat layers of metal effect paint. In other embodiments, applying the one or more metal effect layers comprises (i) applying a semi-transparent primer layer on top of the opaque layer and on portions of the substrate corresponding to the one or more openings, and (ii) applying one or more semi-transparent basecoat layers of metal effect paint applied on top of the primer layer. In some embodiments, the method further comprises applying a transparent or semi-transparent topcoat layer on top of the one or more basecoat layers, the topcoat layer protecting and enhancing the metallic effect of the one or more metal effect layers.

[0023] In some embodiments, applying the opaque layer further comprises applying an initial opaque layer that does not define the one or more openings, and removing portions of the initial opaque layer that correspond to the one or more openings to obtain the opaque layer. In some embodiments, applying the initial opaque layer comprises spraying an opaque primer and curing the sprayed opaque primer to obtain the initial opaque layer. In some embodiments, removing portions of the initial opaque layer comprises laser etching the initial opaque layer. In other embodiments, applying the opaque layer further comprises applying a temporary mask layer to the top surface of the substrate, applying the initial opaque layer by spraying an opaque primer onto the top surface of the substrate and the temporary mask layer, and removing the temporary mask layer and portions of the initial opaque layer associated therewith to obtain the opaque layer. In yet other embodiments, applying the opaque layer comprises digitally printing an opaque material onto portions of the top surface of the substrate.

[0024] In some embodiments, the method further comprises injection or compression molding, thermoforming, or additively manufacturing a plastic material to form the substrate.

[0025] In some embodiments, the trim is a selectively illuminable trim and the method further includes disposing a light source below a bottom surface of the substrate, the light source configured to output light through the substrate, the one or more openings defined by the opaque layer, and the one or more metal effect layers. In some embodiments, the method further includes disposing a light guide plate between the light source and the bottom surface of the substrate, the light guide plate configured to distribute the light output from the light source. In some embodiments, the method further includes packaging the light source and the selectively illuminable trim into a single integrated module.

[0026] According to another aspect of the present disclosure, a method of manufacturing a trim for an object is presented. In one exemplary embodiment, the method includes providing a transparent or translucent substrate defining a top surface and a bottom surface, applying an opaque layer to the bottom surface of the substrate defining one or more openings through which light can pass, and applying one or more translucent metallic effect layers to a top surface of the substrate.

[0027] In some embodiments, applying the one or more metal effect layers comprises applying one or more layers of metal effect paint, while in other embodiments, applying the one or more metal effect layers comprises digitally printing one or more layers of metal effect material.

[0028] In some embodiments, the one or more metal effect layers comprise only one or more basecoat layers of metal effect paint. In other embodiments, applying the one or more metal effect layers comprises (i) applying a semi-transparent primer layer on top of the substrate, and (ii) applying one or more semi-transparent basecoat layers of metal effect paint applied on top of the primer layer. In some embodiments, the method further comprises applying a transparent or semi-transparent topcoat layer on top of the one or more basecoat layers, the topcoat layers protecting and enhancing the metallic effect of the one or more metal effect layers.

[0029] In some embodiments, applying the opaque layer further comprises applying an initial opaque layer that does not define the one or more openings, and removing portions of the initial opaque layer that correspond to the one or more openings to obtain the opaque layer. In some embodiments, applying the initial opaque layer comprises spraying an opaque primer and curing the sprayed opaque primer to obtain the initial opaque layer. In some embodiments, removing portions of the initial opaque layer comprises laser etching the initial opaque layer. In other embodiments, applying the opaque layer further comprises applying a temporary mask layer to a bottom surface of the substrate, applying the initial opaque layer by spraying an opaque primer onto the bottom surface of the substrate and the temporary mask layer, and removing the temporary mask layer and portions of the initial opaque layer associated therewith to obtain the opaque layer. In yet other embodiments, applying the opaque layer comprises digitally printing an opaque material onto portions of a top surface of the substrate.

[0030] In some embodiments, the method further comprises injection or compression molding, thermoforming, or additively manufacturing a plastic material to form the substrate.

[0031] In some embodiments, the trim is a selectively illuminable trim and the method further includes disposing a light source below a bottom surface of the substrate, the light source configured to output light through the substrate, the one or more openings defined by the opaque layer, and the one or more metal effect layers. In some embodiments, the method further includes disposing a light guide plate between the light source and the bottom surface of the substrate, the light guide plate configured to distribute the light output from the light source. In some embodiments, the method further includes packaging the light source and the selectively illuminable trim into a single integrated module.

[0032] Further scope of application of the teachings of the present disclosure will become apparent from the detailed description, claims and drawings provided below. Here, like reference numerals refer to like features throughout the several figures of the drawings. It should be understood that the detailed description, including the disclosed embodiments and drawings referenced herein, are merely exemplary in nature intended for illustrative purposes and are not intended to limit the scope of the present disclosure, its application or method of use. Therefore, variations that do not depart from the material of the present disclosure are intended to be within the scope of the present disclosure. [Brief description of the drawings]

[0033] [Figure 1A] 1A-1C are cross-sectional views of a first embodiment of selectively illuminatable trim in accordance with the principles of the present disclosure for two different user viewing angles; [Figure 1B] 1A-1C are cross-sectional views of a first embodiment of selectively illuminatable trim in accordance with the principles of the present disclosure for two different user viewing angles; [Diagram 2] 4 is a flow chart of a method of manufacturing a first embodiment of a selectively illuminable trim in accordance with the principles of the present disclosure. [Figure 3A] 11A-11C are cross-sectional views of a second embodiment of selectively illuminatable trim in accordance with the principles of the present disclosure for two different user viewing angles; [Figure 3B] 11A-11C are cross-sectional views of a second embodiment of selectively illuminatable trim in accordance with the principles of the present disclosure for two different user viewing angles; [Figure 4A] 1A-1C are cross-sectional views of first and second alternative embodiments of selectively illuminable trim according to the principles of the present disclosure. [Figure 4B] 1A-1C are cross-sectional views of first and second alternative embodiments of selectively illuminable trim according to the principles of the present disclosure. [Diagram 5] 4 is a flow chart of a method for manufacturing a second embodiment of a selectively illuminable trim in accordance with the principles of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0034] Chrome plating also cannot be used for decorative trims with backlighting effects, since it is formed from one or more opaque metal layers that do not allow light to pass through. Chrome plating also attenuates radar wave propagation. Therefore, improvements to selectively illuminable metallic look trims and their manufacturing methods are presented below. In another aspect of the present disclosure, the metallic look trims include a stack of layers with a light source and an optional light guide plate that are packaged together to form a single integrated module. In some embodiments, these trims utilize metallic effect paints and opaque backside layers to obtain an aesthetic metallic look component as chrome plating. In other embodiments, these trims use digital printing to deposit or apply the metallic effect layer instead of using metallic effect paints. In further embodiments, non-metallic effect paints can be used instead of metallic effect paints. For example, matte finish paints can be used. Metallic or non-metallic effect paints can be applied using traditional painting techniques (e.g., rolling, brushing, or spraying). Additionally, metallic or non-metallic paints can be applied using vacuum deposition or electrostatic (e.g., powder coating). In each embodiment, multiple application techniques may also be used, for example, the opaque backing layer may be applied by spraying.

[0035] In a first embodiment, the opaque layer is deposited on the top surface of the substrate, which places the opaque layer closer to the viewer's eye, creating a sharper image with less distortion, such as when viewed at an angle. In a second embodiment, the opaque layer is deposited on the bottom surface of the substrate, which places the opaque layer further from the visual user's eye, creating a more distorted and potentially less sharp image, such as when viewed at an angle. However, this second embodiment has advantages from a processing perspective, since the opaque layer only needs to have a level of adhesion necessary to adhere to the bottom surface of the substrate. These processing advantages can result in reduced costs, which can offset any potential distortion that occurs during viewing. The amount of distortion also varies depending on the thickness of the substrate and the type of light source. Different applications may be considered to have different levels of distortion that are acceptable.

[0036] 1A-1B, a cross-sectional view of a first embodiment of a unitary integrated module 100 is shown. The module 100 comprises a metallic look trim stack 104 formed from multiple stacked layers. A transparent or translucent substrate 108 forms the base of the trim 104. Details of how the substrate 108 is formed are described in detail below with reference to FIG. 2. Non-limiting examples of the substrate 108 include plastic or polymeric materials such as polycarbonate (PC), polymethyl methacrylate (PMMA), acrylonitrile butadiene styrene (ABS), styrene acrylic, styrene acrylonitrile polymers, polyamides, and combinations thereof. In a vehicle trim application, the substrate 108 may be an interior component (such as a dashboard assembly, a center console assembly, a multimedia or infotainment assembly, a door trim panel, etc.) or an exterior body component (such as a front or side grille assembly, bumper or fender accents, headlamp or taillight accents, trunk lid finish, etc.). It will be understood that the systems and methods described herein are not limited to automotive applications, but may also be applied to decorative trim in non-automotive applications, such as appliance and consumer products, rail, motorcycle, aerospace, etc.

[0037] An opaque layer 112 is applied to the top surface of the substrate 108. Details of application of the opaque layer 112 are described in more detail below with reference to FIG. 2. The opaque layer 112 is shown as a black primer layer, but can have any suitable color or composition that prevents or substantially mitigates the transmission of light therethrough. Non-limiting examples of the opaque layer 112 include epoxy-, polyurethane-, and acrylic-based curable wet paints with opaque color pigments, and combinations thereof. Alternatively, the opaque layer 112 may be digitally printed. The opaque layer 112 defines one or more gaps or openings 116 through which light can pass. The one or more openings 116 correspond to designed lighting accent effects, such as, for example, accessories, logos, indicia, icons, motifs, patterns, buttons, or other similar accents on the object associated with the trim. A translucent primer layer 120 is optionally applied to the top surface of the opaque layer 112 and to the top surface of the substrate 108 in areas corresponding to the one or more openings 116. Details of the application of primer layer 120 are described in more detail below with reference to Figure 2. Non-limiting examples of primer layer 120 include epoxy-, polyurethane-, and acrylic-based, clear or translucent curable wet paints, and combinations thereof.

[0038] One or more translucent metallic effect layers 124 are applied on top of the base coat layer 120 (or, if no primer layer 120 is applied, to the opaque layer 112 and to the area of ​​the substrate 108 corresponding to the one or more openings 116). For example, two or more paint layers (base coat layer 120 + single metallic effect paint layer 124, single primer layer 120 + two metallic effect paint layers 124, two metallic effect paint layers 124 (but without primer layer 120), etc.) can be used to achieve optimal aesthetics. Alternatively, the metallic effect layer(s) 124 can be applied by digital printing. Details of the application of the metallic effect layer 124 are described in more detail below with reference to FIG. 2. The metallic effect layer 124 is translucent because it is formed from a paint or printing material that includes elements that are translucent (i.e., at least partially light-transmitting). Such translucent elements include, but are not limited to, transition metals, post-transition metals, metalloids, and combinations thereof (e.g., alloys such as oxides and oxide alloys). For example, a metallic effect paint can be a paint solution that includes flakes of one or more of the elements listed above, it being understood that metallic flakes or similar materials can also be included in the primer layer 120 to further enhance the metallic effect.

[0039] The thickness of the metal effect paint layer 124 should be such that it remains at least translucent when illuminated by a backlight, while appearing metallic when not illuminated. The translucency of the metal layer can also be affected by the chemical composition of the layer and the distribution of each element reflected therein. The metal effect paint layer 124 may also include multiple layers of a single metal effect paint or different metal effect paints applied in various stages to achieve the desired appearance and translucency (i.e., the desired optical properties). For example, FIG. 4A shows one configuration 400 of a trim stack 104 that only requires a single metal effect layer 124 (and no primer layer 120) of one or more undercoat layers of metal effect paint, along with an optional topcoat layer 128, to achieve optimal aesthetics, thereby reducing cost and complexity. As mentioned above, digital printing may be utilized as an alternative to metal effect paint. In particular, one or more metal effect layers can be digitally printed onto the substrate 108, thereby eliminating the need for a primer layer 120.

[0040] An optional topcoat layer 128 may be applied on top of the metal effect layer 124. Details of the application of the optional topcoat layer 128 are described in more detail below with reference to FIG. 2. Non-limiting examples of the topcoat layer 128 include epoxy-, polyurethane-, and acrylic-based clear or translucent curable wet paints, and combinations thereof. The optional topcoat layer 128 may be applied to protect the metal effect layer 124 (e.g., from chipping, peeling, or scratching) and / or to further enhance the appearance of the metal effect layer 124 (e.g., by increasing its apparent gloss). It will be appreciated that the topcoat layer 128 may include metallic flakes or similar materials to further enhance the metallic effect. It will also be appreciated that the topcoat layer 128 may be tinted and / or darkened to further enhance the metallic effect. Non-limiting examples of the above include blue metal effect, copper metal effect, and bronze metal effect, however any light or shade of color combination may be utilized.

[0041] While the various overlayers 112, 120, 124, and 128 are shown to have approximately the same thickness, it will be understood that their actual thicknesses may vary widely and will in most cases be substantially less than the thickness of the substrate 108. In one implementation, the primer layer 120 may have a thickness of 15 μm, the metal effect layer 124 may have a thickness of 1-3 μm, and the topcoat layer 128 may have a thickness of 20-22 μm. This is much thinner than a standard painting process, where the primer layer has a thickness of 20-25 μm, the undercoat paint layer has a thickness of 12-16 μm, and the topcoat layer has a thickness of 30-35 μm. In another implementation, the primer layer 120 may have a thickness of 3-30 μm, the metal effect layer 124 may have a thickness of 1-6 μm, and the topcoat layer 128 may have a thickness of 10-50 μm. In this example, the metal effect paint layer 124 still has a substantially thinner thickness than a conventional painting process.

[0042] The single integrated module 100 further includes a light source 132 (e.g., a light emitting diode (LED), an organic LED (OLED), an optical fiber, an electroluminescent device such as a laser light source, or a similar device) and an optional light guide plate 136 for directing, focusing, or distributing the light generated from the light source 132 through the substrate 108 and one or more openings 116 to form a visible field of view 140. Reference numeral 144 represents the focus or viewing angle of an observer. As shown in FIG. 1A, from a straight-on viewing angle, there is no distortion in the visible field of view 140. In other words, the perceived width 148 of the observer 144 is equal to or approximately equal to the actual width of the visible field of view 140. As shown in FIG. 1B, from an offset or oblique viewing angle, there is very little distortion in the visible field of view 140. As can be seen, the perceived width 152 of the observer 144 is slightly larger than the actual width of the visible field of view 140. Thus, the viewer 144 should still see the intended sharp and clear image when backlit by the light source 132, and should see a shiny metallic looking layer when not backlit by the light source 132.

[0043] Referring now to FIG. 2, a flow diagram of a method 200 for manufacturing a first embodiment of the single integrated module 100 of FIGS. 1A-1B is shown. In step 204, a transparent or translucent substrate is obtained. The substrate 108 can be formed using any suitable plastic or polymer processing technique, examples of which include, but are not limited to, injection molding, extrusion, compression molding, thermoforming, and additive manufacturing (e.g., three-dimensional (3D) printing). As previously mentioned, non-limiting examples of the substrate 108 include plastic or polymeric materials, such as PC, PMMA, ABS, styrene acrylic, styrene acrylonitrile polymers, polyamides, and combinations thereof. In one implementation, the substrate is a plastic interior or exterior body component of a vehicle, as previously described herein.

[0044] In step 208, the opaque layer 112 is applied to the top surface of the substrate 108. In one exemplary embodiment, the opaque layer 112 is applied by spraying an opaque primer and then cured to form an initial opaque layer. The initial opaque layer is then removed (e.g., stripped) to obtain the opaque layer, which corresponds to the one or more openings. For example, laser etching can be used to remove the above-mentioned portions of the initial opaque layer. In another exemplary embodiment, a temporary mask layer is first applied to the top surface of the substrate 108. The temporary mask layer corresponds to the one or more openings 116 defined by the opaque layer 112. The temporary mask layer can be a tape or another adhesive or rigid mask device. Once the temporary mask layer is applied, an opaque primer is sprayed onto the substrate 108 and the temporary mask layer to form the initial opaque layer. The temporary mask layer is then removed, thereby removing the portions of the initial opaque layer corresponding to the one or more openings 116 to obtain the opaque layer 112. As previously mentioned, non-limiting examples of the opaque layer 112 include epoxy-, polyurethane-, and acrylic-based curable wet paints with opaque color pigments, and combinations thereof. In another exemplary embodiment, the opaque layer 112 is an opaque paint that is deposited using a digital printing process, thereby avoiding the need to (i) subsequently define the one or more openings 116 using a laser etching process, or (ii) use a mask to avoid depositing the opaque layer 112 and forming the one or more openings 116.

[0045] In optional step 212, a translucent primer layer 120 is applied to the top surface of the opaque layer 112 and to the substrate 108 in areas corresponding to the one or more openings 116 defined by the opaque layer 112. When applied, the primer layer 120 defines a substantially flat or planar top surface (e.g., flush), while the applied primer layer has a non-uniform thickness (i.e., thicker in areas corresponding to the one or more openings 116 and thinner in other areas). In one exemplary embodiment, the primer layer 120 is applied by spraying a translucent coating, which is then cured to form the primer layer 120. As previously mentioned, non-limiting examples of the primer layer 120 include epoxy-, polyurethane-, and acrylic-based, clear or translucent curable wet paints, and combinations thereof.

[0046] In step 216, a translucent metallic effect layer 124 is applied on top of the undercoat layer 120. The metallic effect layer 124 is applied using any suitable painting or printing process, including but not limited to spraying, brushing, rolling, and digital printing, as well as vacuum processes, such as physical vapor deposition (PVD) and chemical vapor deposition (CVD), or electrostatic deposition (e.g., powder coating). As previously mentioned, the coating solution includes elements that are translucent (i.e., at least partially light-transmitting), including but not limited to transition metals, post-transition metals, metalloids, and combinations thereof (e.g., alloys such as oxides and oxide alloys). For example, the metallic effect coating solution may include flakes of one or more of the above elements. As previously mentioned, the thickness of the metallic effect coating layer 124 should be such that it remains at least translucent when illuminated by a backlight, while appearing metallic when not illuminated. It will also be appreciated that multiple layers of a single metal effect paint, or multiple layers of different metal effect paints, may be applied in different stages to form the metal effect paint layer 124 .

[0047] In optional step 220, an optional transparent or translucent topcoat layer 128 is applied on top of the metal effect layer 124. In one exemplary embodiment, similar to the primer layer 120, the topcoat layer 128 is applied by spraying a transparent or translucent coating and then cured to form the topcoat layer 128. As previously mentioned, non-limiting examples of the topcoat layer 128 include epoxy-, polyurethane-, and acrylic-based transparent or translucent curable wet paints, and combinations thereof. Potential benefits of providing the topcoat layer 128 include providing weather resistance or protection from damage (e.g., chipping, scratching, etc.) to the metal effect layer 124 and / or improving the appearance (e.g., gloss) of the metal effect layer 124. In optional step 224, the light source 132 and optional light guide plate 136 are positioned below the bottom surface of the substrate 108. In optional step 228, the trim stack 104 and light source 132 (and, optionally, the light guide 136) are assembled or packaged into a single integrated module 100. The method 200 then ends.

[0048] 3A-3B, a cross-sectional view of a second embodiment of a unitary integrated module 300 is shown. The module 300 comprises a metallic look trim stack 304 formed from a plurality of stacked layers. The trim stack 304 includes a transparent or translucent substrate 308 having an opaque layer 312 applied to a bottom surface of the substrate 308, the opaque layer 312 defining one or more openings 316. The trim stack 304 further includes an optional translucent primer layer 320, a translucent metallic effect layer 324, and an optional transparent or translucent topcoat layer 328, applied in turn to a top surface of the substrate 308. For example, Figure 4B shows one configuration 450 of trim stack 304 that requires only a single metal effect layer 324 (and no primer layer 320) with optional topcoat layer 328 to achieve optimal aesthetics, thereby reducing cost and complexity. It will be understood that these layers 308-328 may be formed or applied using the same or similar methods and from the same or similar materials as previously described with reference to layers 108-128 of Figures 1A-1B. The same is true for the associated descriptions of light source 332 and optional light guide plate 336 and light source 132 and optional light guide plate 136.

[0049] While the various overlayers 312, 320, 324, and 328 are shown to have approximately the same thickness, it will be understood that their actual thicknesses may vary widely and will in most cases be substantially less than the thickness of the substrate 308. In one implementation, the primer layer 320 may have a thickness of 15 μm, the metal effect layer 324 may have a thickness of 1-3 μm, and the topcoat layer 328 may have a thickness of 20-22 μm. This is much thinner than a standard paint process, where the primer layer has a thickness of 20-25 μm, the undercoat paint layer has a thickness of 12-16 μm, and the topcoat layer has a thickness of 30-35 μm. In another implementation, the primer layer 320 may have a thickness of 3-30 μm, the metal effect layer 324 may have a thickness of 1-6 μm, and the topcoat layer 328 may have a thickness of 10-50 μm. In this example, the metal effect paint layer 324 still has a thickness that is substantially less than a conventional paint process. As mentioned above, digital printing may be utilized as an alternative to metal effect paints. Specifically, one or more metal effect layers may be digitally printed onto the substrate 308, thereby eliminating the need for the primer layer 320.

[0050] The main difference between module 100 and module 300 is that opaque layer 312 is applied to the bottom surface of substrate 308 in module 300. There may also be an optional transparent or semi-transparent undercoat layer 318 applied to the bottom surface of substrate 308 in the area corresponding to one or more openings 316 so that the bottom surface (side B) of trim stack 304 is flush. This undercoat layer 318 may be the same or similar material as optional primer layer 320 and / or optional topcoat layer 328 and may be applied using the same or similar process (e.g., masking). As shown in FIG. 3A, from a straight-on viewing angle (see reference number 344 representing observer 344), there is no distortion of visible field of view 340. In other words, the perceived width 348 of observer 344 is equal to or approximately equal to the actual width of visible field of view 340.

[0051] However, as shown in FIG. 3B, from an offset or oblique viewing angle, there is a very large distortion of the visible field of view 340. As can be seen, the perceived width 352 of the observer 344 is substantially larger than the actual width of the visible field of view 340. Thus, the observer 144 sees a less sharp (i.e., slightly distorted) image when backlit by the light source 332, while seeing a shiny, metallic looking layer when not backlit by the light source 332. However, one advantage of the configuration of the module 300 is that it is easier to process or form. More specifically, the opaque layer 312 must be designed or selected solely for adhesion to the substrate 308, and not for adhesion to both the substrate 308 and the primer layer 320 (as is required for the opaque layer 112 in FIGS. 1A-1B with respect to the substrate 108 and the primer layer 120).

[0052] Referring now to FIG. 5, there is shown a flow diagram of a method 500 for manufacturing a second embodiment of a single integrated module 300. It will again be appreciated that the same or similar processes or methods as previously described in connection with FIGS. 1A-1B, 2, and 4A may be utilized to form the module 300 of FIGS. 3A-3B, and 4B, and for the method 500. In step 504, a transparent or translucent substrate 308 is obtained. In step 508, an opaque layer 312 defining one or more openings 316 is applied to the backside of the substrate 308. Although described and shown as a second processing step after obtaining the substrate 308, it will be appreciated that the opaque layer 312 may be applied after application of the optional translucent primer layer 320, the translucent metal effect layer 324, and the optional transparent or translucent topcoat layer 328, or between the application of these layers 320-328, and prior to steps 528 and 532.

[0053] In optional step 512, a primer layer 320 is applied to the top surface of the substrate 308. In step 516, a metal effect layer 324 is applied to the top surface of the primer layer 320 using conventional means (e.g., spraying, brushing, rolling, and digital printing), as well as vacuum processes such as physical vapor deposition (PVD) and chemical vapor deposition (CVD), or electrostatic deposition (e.g., powder coating). In optional step 520, an overcoat layer 328 is applied to the top surface of the metal effect layer 324. In optional step 524, a light source 332 and an optional light guide plate 336 are positioned below the bottom surface of the trim stack 304. In optional step 428, the trim stack 304 and the light source 332 (and optionally the light guide plate 336) are assembled or packaged into a single integrated module 300. The method 500 then ends.

[0054] The exemplary embodiments are provided so that the disclosure is thorough and fully conveys the scope to those skilled in the art. Numerous specific details are described, such as examples of specific components, devices, and methods, to provide a thorough understanding of the embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, and that the exemplary embodiments may be embodied in many different forms and should not be construed as limiting the scope of the present disclosure. In some exemplary embodiments, well-known process procedures, well-known device structures, and well-known technologies are not described in detail.

[0055] The terms used herein are for the purpose of describing particular exemplary embodiments only and are not intended to be limiting. As used herein, the singular articles "a," "an," and "the" may be intended to include the plural unless the context clearly indicates otherwise. The term "and" includes any and all combinations of one or more of the associated listed items. The terms "comprises / comprising," "including," and "having" are inclusive and thus specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. The steps, processes, and operations of the methods described herein should not be construed as necessarily requiring their performance in the particular order described or illustrated, unless specifically identified as an order of performance. It is also understood that additional or alternative steps may be used.

[0056] Terms such as first, second, third, etc. may be used herein to describe various elements, components, regions, layers, and / or sections, but these elements, components, regions, layers, and / or sections should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or section from another region, layer, or section. As used herein, terms such as "first," "second," and other numerical terms do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer, or section described below can be referred to as a second element, component, region, layer, or section without departing from the teachings of the exemplary embodiments.

[0057] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the present disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but where applicable, even if not specifically shown or described, individual elements or features of a particular embodiment are interchangeable and can be used in selected embodiments. Similarly, they may be modified in many ways. Such modifications should not be considered as a departure from the present disclosure, and all such modifications are intended to be included within the scope of the present disclosure.

[0058] It will be appreciated that mixing and matching of features, elements, methods, and / or functions between various embodiments may be expressly contemplated herein, and thus, those skilled in the art will understand that, unless otherwise stated in the description above, features, elements, and / or functions of one embodiment may be expressly contemplated herein.

Claims

1. A trim for an object, comprising: a transparent or translucent substrate defining an upper surface; an opaque layer applied to the top surface of the substrate, the opaque layer defining one or more openings through which light can pass; one or more semi-transparent metallic effect layers applied on top of the opaque layer; the opaque layer is an opaque paint selected from epoxy-, polyurethane-, and acrylic-based curable wet paints having opaque color pigments, and combinations thereof; said one or more translucent metallic effect layers comprising a basecoat layer, a metallic effect paint layer, and a topcoat layer; the overcoat layer protects the one or more translucent metallic effect layers; The topcoat layer is (i) containing metal particles; and (ii) Trim that is at least one of: lightly or darkly colored.

2. The trim of claim 1 , wherein the one or more translucent metallic effect layers comprise one or more layers of digitally printed metallic effect material.

3. said one or more semi-transparent metallic effect layers being (i) a translucent primer layer applied to the top surface of the opaque layer and to portions of the substrate corresponding to the one or more openings; and 10. The trim of claim 1, further comprising: (ii) one or more semi-transparent basecoat layers applied on top of said primer layer.

4. 4. The trim of claim 1, wherein the trim is a selectively illuminatable trim, further comprising a light source disposed beneath a bottom surface of the substrate and configured to output light through the substrate, the one or more openings defined by the opaque layer, and the one or more metallic effect layers.

5. The trim of claim 4 , further comprising a light guide disposed between the light source and the bottom surface of the substrate and configured to distribute the light output from the light source.

6. 1. A method of manufacturing a trim for an object, comprising: providing a transparent or translucent substrate defining a top surface and a bottom surface; applying an opaque layer to the top surface of the substrate, the opaque layer defining one or more openings through which light can pass; applying one or more semi-transparent metallic effect layers on top of said opaque layer; The opaque layer is applied by painting or printing, and the opaque layer is an opaque paint selected from epoxy-, polyurethane-, and acrylic-based curable wet paints having opaque color pigments, and combinations thereof; applying the one or more translucent metallic effect layers comprises applying a basecoat layer, a metallic effect paint layer, and a topcoat layer; the overcoat layer protects the one or more semi-transparent metallic effect layers; The topcoat layer is (i) containing metal particles; and (ii) being colored lightly or darkly.

7. The method of claim 6 , wherein applying the one or more metal effect layers comprises digitally printing one or more layers of metal effect material.

8. applying said one or more metal effect layers (i) applying a translucent primer layer to the top surface of the opaque layer and to portions of the substrate corresponding to the one or more openings; and 8. The method of claim 7, comprising: (ii) applying one or more semi-transparent undercoat layers of a metallic effect paint applied on top of said primer layer.

9. applying said opaque layer applying an initial opaque layer that does not define the one or more openings; and The method of any one of claims 6 to 8, further comprising removing portions of the initial opaque layer corresponding to the one or more openings to obtain the opaque layer.

10. applying said initial opacity layer Spraying an opaque primer; and curing the sprayed opaque primer to obtain the initial opaque layer; Including, The method of claim 9 , wherein removing portions of the initial opaque layer comprises laser etching the initial opaque layer.

11. applying said opaque layer applying a temporary mask layer to the one of the top and bottom surfaces of the substrate; applying an initial opaque layer by spraying an opaque primer onto the one of the top and bottom surfaces of the substrate and the temporary mask layer; The method of any one of claims 6 to 8, further comprising removing the temporary mask layer and portions of the initial opaque layer associated with the temporary mask layer to obtain the opaque layer.

12. The method of any one of claims 6 to 8, wherein applying the opaque layer comprises digitally printing an opaque material onto portions of the top surface of the substrate.

13. The method of any one of claims 6 to 12, further comprising injection or compression moulding, thermoforming or additively manufacturing a plastic material to form the substrate.

14. the trim is selectively illuminatable trim; The method further comprising: disposing a light source beneath the bottom surface of the substrate, the light source being configured to output light through the substrate, the one or more openings defined by the opaque layer, and the one or more metallic effect layers; and The method of any one of claims 6 to 13, further comprising packaging the light source and the selectively illuminable trim in a single integrated module.

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