Production of a filled decoration by means of contour element

Abstract

The invention proposes a method for producing a filled decoration (100) for a motor vehicle. The method has the step (S110) of providing a decorative element (110), wherein the decorative element (110) has at least one opening (115) which is designed to be filled with filling material, and the step (S120) of providing a contour element (120), wherein the contour element (120) has at least one thickened portion (125) which is made from the filling material. The method furthermore has the step (S130) of positioning the contour element (120) and the decorative element (110) with respect to one another such that the at least one thickened portion (125) of the contour element (120) is opposite the at least one opening (115) of the decorative element (110), and the step (S140) of pressing the contour element (120) and the decorative element (110) together.

Description

[0001] PRODUCTION OF A FILLED DECOR USING A CONTOUR ELEMENT

[0002] Technical area

[0003] The present invention relates to a method for producing a filled decoration for a motor vehicle. The invention also relates to a contour element and a filled decoration.

[0004] State of the art

[0005] In the prior art, decorations, especially openings in their surfaces, are usually filled with a liquid or flowable material. This can be applied, for example, to the back of the decoration using a roller and then introduced into the corresponding openings or opening areas. However, this often leads to extensive contact of the decoration with the liquid filling material and does not allow for precise filling of individual areas of the decoration.

[0006] The inventors of the present invention found that it would be advantageous to use an improved method which allows a narrow, selective filling of individual areas of a decoration and enables a material- and cost-saving filling of openings in the decoration.

[0007] Description of the invention

[0008] An object of the invention is therefore to propose an improved method for producing a filled decoration for a motor vehicle, which overcomes the disadvantages of the current state of the art and enables a dimensionally accurate and efficient filling of openings of a decorative element with a filling material.

[0009] The object is achieved by the subject matter of the independent claims. Advantageous developments of the invention are specified in the dependent claims, the description, and the accompanying figures. The described embodiments apply equally to the method for producing a filled decoration for a motor vehicle, the contour element, and the filled decoration. Synergistic effects can arise from various combinations of the embodiments, even if they are not described in detail.

[0010] Furthermore, it should be noted that all method-related embodiments of the present invention can be carried out in the described order of steps. Nevertheless, this need not be the only possible or required order of steps in the method. The methods described herein can be carried out in a different order of the disclosed steps without deviating from the corresponding method embodiment, unless expressly stated otherwise below.

[0011] According to a first aspect of the invention, a method for producing a filled decoration for a motor vehicle is proposed. The method comprises the step of providing a decorative element, wherein the decorative element has at least one opening designed to be filled with a filling material. Furthermore, the method comprises the step of providing a contour element, wherein the contour element has at least one thickened portion made of the filling material. The method comprises the step of positioning the contour element and the decorative element relative to one another such that the at least one thickened portion of the contour element is opposite the at least one opening of the decorative element, and the step of pressing the contour element to the decorative element.

[0012] According to the method of the present invention, a contour filling piece or a contour filling element is manufactured from an adhesive material for the production of a borderlessly filled decoration or light decoration, which is suitable, for example, for backlighting or transillumination, for example with LEDs or RGBs, optionally with or without area lights. The contour element is preferably manufactured from a light-transparent polymer or an adhesive such as a dispersion or a hotmelt, which can be preformed for a contour element and is suitable for final bonding or pressing with an opened decoration. The contour element can be manufactured, for example, using a mold or device, which preferably has a separating contour surface or separating surface, which can be designed to be heatable or non-heatable.The contour element has a different, varying thickness with elevations, thickenings, and / or positive structures. The final contour of the contour element with the at least one thickening can either be produced by the forming tool itself or by an additional embossing tool from a pre-product of the contour element, whereby the pre-product can also be flat or planar. The decorative element, or its at least one opening, is to be filled with the material of the contour element. Optionally, the provided decorative element or a decorative composite can preferably be pre-coated on the back and have openings, lines, symbols, or emblems. The filling or fill-coating of the decoration to be filled can be carried out using a pressing tool, a pressing device, or a pressing system, whereby this can be carried out both with and without tempering or pre-tempering of the contour element.After positioning and optionally securing the decorative element and the contour element to each other, they are pressed together, whereby the thickened portion of the contour element is pressed into the opening, with or without a recess, of the decorative element and fills it. Optionally, after pressing, a subsequent pressing or cleaning step can take place, for example, removing any filling material of the contour element that was not pressed into or removed from the at least one opening of the decorative element.

[0013] Thus, the method according to the invention advantageously enables the partial or selective filling of openings on a decoration or decorative composite using a manufactured adhesive contour filling piece or contour filling element by pressing, pressing in or embossing, wherein the filling material of the contour element or contour filling element can be a dispersion, a hot melt, an adhesive, or a reactive or non-reactive polymer.

[0014] Partial or selective filling can also be understood as narrow-area filling and is made possible by the method according to the invention, which is not the case, for example, with conventional roller coating with at least one larger run-out area. This advantageously ensures borderless or seamless integration of, for example, just one function symbol on an instrument panel surface, for example on the opened decor or decor composite. Larger-area, rear-side coatings of the decor element can thus be avoided. Precise filling or filling coating is possible by fixing and positioning an adhesive contour filling piece or contour element on the decor, which avoids large-area contact of the decor with a liquid filling material, as would occur, for example, with roller coating.This avoids major effects caused by chemical interactions between the filling material and the decor, such as negative absorption or capillary behavior, especially with fibrous decors. This also eliminates the need for large-scale, time-consuming pre-coating of the decor, such as on the textile backing of artificial leather or a textile, eliminating a single work step. Compared to roller or doctor blade coating, this results in material and cost savings, particularly due to the reduction in work steps.

[0015] When designing and implementing a contour filling element, factors such as size, thickness, material properties (e.g., porous or non-porous), the opening sizes or opening areas to be filled, or the size of a lighting design on the decor can be considered. Materials that can be filled with an adhesive contour element can include leather, synthetic leather, textiles, or wood, with the nominal thickness of the contour element preferably corresponding to the thickness of the decor to be filled. Decorative materials or decorative composites can also consider improved sustainability and be made from renewable raw materials, for example. An embossed contour can also be considered, for example, in an embossed contour filling element that takes into account structures with elevations and depressions, for example.

[0016] Furthermore, the fill quantity that can be applied to a decor with the inventive method of pressing on an individually designed contour filling element is not subject to the limitations or restrictions of, for example, a roller or doctor blade process, in which openings in thick decors, for example, can be difficult to fill. This can be due to the technology itself or to the different absorption behavior of fibrous decors, and can also cause waviness in the decors. This provides a greater degree of technological freedom, such as a wider spectrum of fillable decors. Optionally, compensation for particularly strong shrinkage forces, e.g., in leather, can be provided through the use of a contour element with a textile reinforcement.Alternatively, the contour element can be bonded to a layered material such as a textile, nonwoven fabric, or film before being used for filling. The contour filling piece or contour filling element can also be suitable for pre-fixing or have pre-fixing properties.

[0017] The method according to the invention can be used, for example, in the production of two-dimensional or three-dimensional light decorations, in sharply split, split or non-sharply split, split decorations such as leather, in pre-filled openings, or in the filling of decorations with existing transparent residual wall thicknesses made of film, polymer, etc. For example, a light decoration can also be designed three-dimensionally, for example with facet-like real stones or imitation stones made of glass, polymer, wood or metal, which are transparent and optionally connected to a housing via the contour element with a decoration such as artificial leather. Other material combinations are also possible. For example, leather can be connected to an acoustically capable textile, such as a knitted or crocheted fabric, via the contour element.

[0018] Furthermore, multiple contour elements can be provided, with or without separating areas where individual elements can be optionally separated. The contour element, especially a multiple contour element, can also have openings for speakers, ventilation, or similar devices, or can run straight or meandering in the edge area, as is advantageous for so-called "seamless" integration.

[0019] Advantageously, the contour element can be made in particular from a non-reactive dispersion without isocyanate.

[0020] Decorations produced by the process according to the invention are preferably used in motor vehicles, as interiors, for example in the center console, in the instrument panel, or in the doors, and preferably in lighting decorations.

[0021] In one embodiment of the invention, the step of pressing the contour element with the decorative element comprises pressing at least a part of the filling material of the at least one thickening of the contour element into the at least one opening of the decorative element, or pressing the decorative element into the contour element.

[0022] In one embodiment of the invention, the step of providing the contour element comprises embossing and / or pressing the contour element to produce the at least one thickened portion. The thickened portion on a contour element can also be produced by other methods, such as by means of a tool falling over a tool cavity, or by injection, spraying, etc.

[0023] In one embodiment of the invention, the filling material is adhesive, and / or the filling material is a polymer, an adhesive, a dispersion, a hot melt, a varnish, a printing ink, or a combination thereof.

[0024] In one embodiment of the invention, the contour element has a reinforcing structure, and the at least one thickened portion of the contour element is applied to the reinforcing structure. The material of the thickened portion can also penetrate into or fill the material of the reinforcing structure, textile, or spacer fabric.

[0025] In one embodiment of the invention, the contour element is designed to be arranged on the decorative element, and a position of the at least one thickening of the contour element corresponds to a position of the at least one opening of the decorative element. Additionally or alternatively, the thickening in the thickness profile can be a so-called "varying thickening." The shape or geometry of the thickening does not have to correspond to the shape of the opening and / or a rear-side thinning / recess. The thickening can, for example, also be positioned offset from the opening of the decorative element. The process of pressing depends, among other things, on the pressing method used, so that, for example, rolling pressing, for example using rollers with a sliding table / traversing table, may require a different position of the thickening than pressing with a double roller or a horizontal press.

[0026] In one embodiment of the invention, the at least one thickened portion of the contour element is arranged substantially in the region of the at least one opening of the decorative element, and / or a shape of the at least one thickened portion of the contour element substantially corresponds to a shape of the at least one opening of the decorative element. In particular, however, the geometry of the contour element and the geometry of the openings to be filled, with or without a recess, are preferably not identical before filling, since filling compression is preferably a displacement process. The geometry of the contour element can be designed such that process fluctuations, such as dimensional inaccuracies with regard to positioning, etc., can be compensated.

[0027] In one embodiment of the invention, the contour element has a plurality of thickenings, the decorative element has a plurality of openings, and a shape and position of the plurality of thickenings of the contour element substantially corresponds to a shape and position of the plurality of openings of the decorative element.

[0028] In one embodiment of the invention, the contour element has two or more layers of different materials, which together form the contour element and are pressed into the decorative element.

[0029] In one embodiment of the invention, the contour element has two or more layers, which may optionally consist of different materials, and the two or more layers are pressed one after the other into an opening of the decorative element.

[0030] According to a further aspect of the invention, a contour element for use in the method according to one of the preceding embodiments is proposed.

[0031] According to a further aspect of the invention, a filled decoration is proposed which is produced according to the method according to one of the preceding embodiments.

[0032] Thus, the benefits offered by one of the above-mentioned aspects apply equally to all other aspects and vice versa.

[0033] Essentially, the invention relates to a method for producing a filled decoration for a motor vehicle. The method comprises the step of providing a decorative element, wherein the decorative element has at least one opening designed to be filled with a filling material, and the step of providing a contour element, wherein the contour element has at least one thickened portion made of the filling material. The method further comprises the step of positioning the contour element and the decorative element relative to one another such that the at least one thickened portion of the contour element is opposite the at least one opening of the decorative element, and the step of pressing the contour element onto the decorative element.

[0034] Further features, advantages and possible applications of the invention will become apparent from the following description of advantageous embodiments and the accompanying figures.

[0035] Short character description

[0036] An advantageous embodiment of the invention is explained below with reference to the accompanying figures.

[0037] Fig. 1 shows a block diagram of a method for producing a filled decoration for a motor vehicle according to an embodiment of the invention.

[0038] Fig. 2 shows a schematic representation of a method for producing a filled decoration for a motor vehicle according to an embodiment of the invention.

[0039] Fig. 3 shows schematic representations of contour elements according to embodiments of the invention.

[0040] Fig. 4 shows schematic representations of contour elements according to embodiments of the invention.

[0041] Fig. 5 shows schematic representations of contour elements according to embodiments of the invention.

[0042] Fig. 6 shows schematic representations of decorative elements and contour elements according to embodiments of the invention. Fig. 7 shows a photographic representation of a textile-reinforced and embossed decoration according to one embodiment of the invention.

[0043] Fig. 8 shows schematic representations of the production of a contour element according to an embodiment of the invention.

[0044] Fig. 9 shows a schematic representation of multi-layer contour elements according to an embodiment of the invention.

[0045] Fig. 10 shows a photographic representation of a decoration with three-dimensional elements according to an embodiment of the invention.

[0046] The figures are merely schematic representations and serve only to illustrate the invention. Identical or equivalent elements are provided with the same reference numerals throughout.

[0047] Detailed description

[0048] Fig. 1 shows a block diagram of a method for producing a filled decoration 100 for a motor vehicle according to an embodiment of the invention. The method comprises step S110 of providing a decorative element 110, wherein the decorative element 110 has at least one opening 125 designed to be filled with a filling material, and step S120 of providing a contour element 120, wherein the contour element 120 has at least one thickened portion 125 made of the filling material. The method further comprises step S130 of positioning the contour element 120 and the decorative element 110 relative to one another such that the at least one thickened portion 125 of the contour element 120 is opposite the at least one opening 115 of the decorative element 110, and step S140 of pressing the contour element 120 to the decorative element 110.

[0049] Fig. 2 shows a schematic representation of a method for producing a filled decoration 100 for a motor vehicle according to one embodiment of the invention. The upper part of the figure shows a contour element 120 with a thickened portion 125, which is arranged next to a decorative element 110 with an opening 115 associated with the thickened portion 125. The lower half of the figure shows the finished filled decoration 100 after pressing, with the thickened portion 125 of the contour element 120 pressed into the opening 115 of the decorative element 110.

[0050] Fig. 3 shows schematic representations of contour elements 120 according to embodiments of the invention. In particular, the contour elements 120 differ in the shape of the respective thickened portion 125. While the contour element 120 under a) has a square shape, the contour elements 120 under b) and c) are rounded. The contour element 120 under d) can be straight or, for example, meandering in the edge region. The contour elements 120 under e) and f) have thickened portions 125 on both sides that are asymmetrical or symmetrical with respect to a center plane of the contour element 120.

[0051] Fig. 4 shows schematic representations of contour elements according to embodiments of the invention. The contour element 120 shown under a) can be formed from two different materials. Both of the parts of the contour element 120 consisting of different materials can have a contour such as a thickening 125, or only one of the parts of the contour element 120 can have a contour such as a thickening 125, while the other part represents a flat layer. One or both parts can be transparent. One of the transparent layers can be a colored transparent layer. The transparent layers can also be of varying transparency or translucentness. The contour element 120 shown under b) has a textile reinforcement as a reinforcing structure 130, to which the thickening 125 of the contour element 120 is attached.The embodiment of a contour element 120 shown under c) is adapted to a pre-embossed decorative element 110.

[0052] Fig. 5 shows schematic representations of contour elements 120 according to embodiments of the invention. In particular, manufactured overall contour elements with a plurality of thickened portions 125 are shown, which can be separated as individual contour elements 120 by means of optional separation areas, if desired. In addition, decorative elements 110 with a plurality of openings 115 are shown. The contour profiles are, for example, continuously decreasing or increasing in a continuous manner, or continuously decreasing or increasing in steps. For example, the contour profile can also follow the contour of a sharpening split. Figure 5 also shows a thickened portion with a varying thickness profile. The shape or geometry of the thickened portion does not necessarily correspond to the shape of the opening or a thinning / recess on the rear side. The thickened portion can, for example, also be positioned offset from the opening of the decorative element.

[0053] Fig. 6 shows schematic representations of decorative elements 110 and contour elements 120 according to embodiments of the invention. The decorative element 110 shown in Fig. 6A has linear openings 115, while the filler coating element or contour element 120 shown in Fig. 6B has wave-like elevations or thickenings 125. These can be pressed into the openings 115 of the decorative element 110. The filler coating element or contour element 120 shown in Fig. 6C.

[0054] In addition to the wave-like elevations, the contour element 120 also has material webs that connect the wave-like elevations. The contour element 120 is preferably trimmed so that only the connecting material webs and the individual "contour elements" remain, thus removing any remaining material before the contour element is positioned on the decorative element. Optionally, the connecting material webs can be removed before final pressing.

[0055] Fig. 7 shows a photographic representation of a textile-reinforced and embossed decorative element 100 according to one embodiment of the invention. This decorative element was produced according to the method of the present invention. In particular, a contour element 120 was pressed onto a decorative element 110.

[0056] Fig. 8 shows schematic representations of the production of a contour element 120 according to one embodiment of the invention. In this embodiment, two flat adhesive films are joined and optionally trimmed. The adhesive layers can be implemented with or without a colored lacquer layer. The adhesive can also be colored transparent or optionally uncolored. After joining, the adhesive layers are deformed to produce the contour element 120 according to the invention with a thickened portion 125. This can then be pressed into an opening 115 of a decorative element 110.

[0057] Fig. 9 shows a schematic representation of multi-layer contour elements 120 according to one embodiment of the invention. In this embodiment, a multi-layer contour element 120 made from individual contour elements 121, 122 is used. This allows a decor 100 or decorative composite with at least one opening 115 to be fill-coated. For this purpose, the first individual contour element 121 is first pressed into an opening 115 of the decor 110, for example using a high-pressure forming (HPF) process. The first individual contour element 121 can, for example, consist of adhesive, which can be colored transparent, or transparent and uncolored and thus clear. Optionally, a layer of color can be applied to the first individual contour element 121.Subsequently, by activating the first individual contour element 121 and / or the second individual contour element 122, the second individual contour element 122 can be pressed onto the first individual contour element 121 from the back. The second individual contour element 122 can be made of adhesive or a thermoplastic, for example, whereby the second individual contour element 122 is preferably transparent and not colored. In an alternative manufacturing method, the first individual contour element 121 can be joined to the second individual contour element 122 with or without additional adhesive, for example by laminating. The composite of the two individual contour elements 121, 122 can then be inserted into the decoration by heating.

[0058] Fig. 10 shows a photographic representation of a decoration 100 with three-dimensional elements according to one embodiment of the invention. The faceted real stones or imitation stones made of glass, polymer, wood, or metal can be transparent and optionally connected to a housing via the contour element with a decoration such as artificial leather, whereby other material combinations are also possible.

[0059] Although the invention has been illustrated and described in detail in the drawings and the foregoing description, these drawings and descriptions are to be considered as illustrative or exemplary in nature and not as restrictive. The invention is not limited to the disclosed embodiments. Other variations of the disclosed embodiments may be understood and practiced by those skilled in the art to practice the claimed invention, based on the drawings, the disclosure, and the dependent claims.

[0060] Additionally, it should be noted that "comprising" does not exclude other elements or steps, and "one" or "an" does not exclude a plurality. Furthermore, it should be noted that features or steps described with reference to one of the above embodiments may also be used in combination with other features or steps of other embodiments described above. Reference symbols in the claims are not to be considered as limiting. LIST OF REFERENCE SYMBOLS

[0061] 100 decor

[0062] 110 Decorative element 115 Opening

[0063] 120 contour element

[0064] 121 first contour element

[0065] 122 second contour single element

[0066] 123 Paint layer 125 Thickening

[0067] 130 Reinforcement structure

Claims

CLAIMS 1 . A method for producing a filled decoration (100) for a motor vehicle, the method comprising the steps: Providing (S110) a decorative element (110), wherein the decorative element (110) has at least one opening (115) which is designed to be filled with a filling material; Providing (S120) a contour element (120), wherein the contour element (120) has at least one thickening (125) made of the filling material; Positioning (S130) the contour element (120) and the decorative element (110) relative to each other such that the at least one thickened portion (125) of the contour element (120) is opposite the at least one opening (115) of the decorative element (110); and Pressing (S140) the contour element (120) with the decorative element (110).

2. The method according to claim 1, wherein the step of pressing the contour element (120) with the decorative element (110) comprises pressing at least a part of the filling material of the at least one thickening (125) of the contour element (120) into the at least one opening (115) of the decorative element (110), or pressing the decorative element (110) into the contour element (120).

3. The method according to one of claims 1 or 2, wherein the step of providing the contour element (120) comprises embossing and / or pressing the contour element (120) to produce the at least one thickening (125).

4. The method according to any one of the preceding claims, wherein the filling material is adhesive, and / or wherein the filling material is a polymer, an adhesive, a dispersion, a hot melt, a varnish, a printing ink, or a combination thereof.

5. The method according to one of the preceding claims, wherein the contour element (120) has a reinforcing structure (130), and wherein the at least one thickening (125) of the contour element (120) is attached to the reinforcing structure (130).

6. The method according to one of the preceding claims, wherein the contour element (120) is designed to be arranged on the decorative element (110), and wherein a position of the at least one thickening (125) of the contour element (120) corresponds to a position of the at least one opening (115) of the decorative element (110).

7. The method according to one of the preceding claims, wherein the at least one thickening (125) of the contour element (120) is arranged substantially in the region of the at least one opening (115) of the decorative element (110), and / or wherein a shape of the at least one thickening (125) of the contour element (120) substantially corresponds to a shape of the at least one opening (115) of the decorative element (110).

8. The method according to one of the preceding claims, wherein the contour element (120) has a plurality of thickened portions (125), wherein the decorative element (110) has a plurality of openings (115), and wherein a shape and position of the plurality of thickened portions (125) of the contour element (120) substantially corresponds to a shape and position of the plurality of openings (115) of the decorative element (110).

9. A contour element (120) for use in the method according to any one of claims 1 to 8.

10. A filled decoration (100) produced by the method according to one of claims 1 to 8.

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