Exterior trim part of a vehicle and method for producing an exterior trim part

Abstract

The invention relates to an exterior trim part (1) of a vehicle, comprising a thin-walled cover element (2) for covering and protecting a device (3) for emitting and / or receiving electromagnetic waves against environmental influences, wherein the cover element (2) has an intended visible side (A) and an inner side (B) opposite the visible side (A) and is configured such that it can be penetrated by electromagnetic waves of at least one electromagnetic wavelength in the range of 100 nm to 1600 nm, wherein the cover element (2) furthermore has at least one carrier layer (4) made of a polymer material which is transparent or partially transparent to the electromagnetic waves, and having at least one layer (5) of an anti-reflection coating and / or anti-reflection structuring, which is designed in such a way that it reduces the reflection of the provided electromagnetic waves off the cover element (2), wherein the layer (5) is arranged at least on the region (X) of the carrier layer (4) through which the electromagnetic waves are to pass, wherein the wall thickness of the cover element (2) is in a range of 1 mm to 8 mm, preferably in the range of 1.5 mm to 5 mm.

Description

[0001] RESRG Automotive SE & Co. KG Rehau, March 27, 2025 Int. Ref: 24.097 / 2 dr.lauk

[0002] Exterior trim part of a vehicle and method for manufacturing an exterior trim part

[0003] The present invention relates to an exterior trim part of a vehicle, comprising a thin-walled cover element for covering and protecting a device for transmitting and / or receiving electromagnetic waves from environmental influences, wherein the cover element has a designated visible side and an inner side opposite the visible side and is configured such that it can be penetrated by electromagnetic waves with a wavelength in the range of 100 nm to 1600 nm, wherein the cover element further comprises:

[0004] at least one carrier layer made of a polymer material that is transparent or partially transparent to electromagnetic waves,

[0005] at least one layer of an anti-reflective coating and / or anti-reflective structuring designed to reduce the reflection of the intended electromagnetic waves at the cover element, wherein the layer is arranged at least on the area of ​​the substrate layer to be penetrated by the electromagnetic waves,

[0006] wherein the wall thickness of the cover element is in a range of 1 mm to 8 mm, preferably in the range of 1.5 mm to 5 mm.

[0007] A corresponding exterior cladding component is disclosed in document DE 102018 109884 B4. An anti-reflective coating is provided on a film with conductive traces. The film is bonded to the substrate by overmolding the film with the substrate material in an injection molding process.

[0008] Such a process is complex, and moreover, a film can slip during the injection molding process, so that it is not, or not completely, within the emission or reception range of the device.

[0009] The object of the present invention is therefore to provide an exterior trim component that can be manufactured more reliably. RESRG Automotive SE & Co. KG Rehau, March 27, 2025 Int. Ref: 24.097 / 2 dr.lauk

[0010] This task is solved by an exterior panel of a vehicle, with a thin-walled cover element for covering and protecting a device for transmitting and / or receiving electromagnetic waves from environmental influences.

[0011] wherein the cover element has a designated visible side and an inner side opposite the visible side and is configured in such a way that it can be penetrated by electromagnetic waves of at least one electromagnetic wavelength in the range of 100 nm to 1600 nm,

[0012] the cover element further comprises:

[0013] at least one carrier layer made of a polymer material that is transparent or partially transparent to electromagnetic waves,

[0014] at least one layer of an anti-reflective coating and / or anti-reflective structuring designed to reduce the reflection of the intended electromagnetic waves at the cover element, wherein the layer is arranged at least on (and limited to) the area of ​​the substrate layer to be penetrated by the electromagnetic waves,

[0015] wherein the wall thickness of the cover element is in a range of 1 mm to 8 mm, preferably in the range of 1.5 mm to 5 mm,

[0016] wherein the antireflection coating and / or antireflection structuring layer is composed of at least two superimposed single layers, wherein the refractive index of the first single layer arranged on the substrate layer is lower than the refractive index of the polymer material of the substrate layer, and wherein the refractive index of the second single layer arranged above the first single layer is lower than the refractive index of the first single layer.

[0017] Antireflection structuring is based on the use of structures smaller than the wavelength of visible light. These structures are often referred to as "moth-eye" structures because they resemble the structure of moth eyes, which reflect light. RESRG Automotive SE & Co. KG Rehau, March 27, 2025 Int. Ref: 24.097 / 2 dr.lauk

[0018] Minimize and maximize light transmission. These structures are built using various nanofabrication methods such as lithography, etching, or self-assembly. The resulting structures can have conical, pyramidal, or columnar shapes, for example, which scatter the incident light and reduce reflection through destructive interference.

[0019] Both an anti-reflection coating and an anti-reflection structuring can be described as transmission-enhancing layers.

[0020] It may be provided that the layer is arranged at least on the area of ​​the support layer to be penetrated by the electromagnetic waves and is limited to this area.

[0021] It may be provided that the layer of antireflection coating and / or antireflection structuring is composed of at least three individual layers arranged one above the other, wherein the refractive index of the third individual layer arranged above the second individual layer is lower than the refractive index of the second individual layer.

[0022] It may be provided that at least one of the individual layers of the layer is applied using an inkjet printing process. It may also be provided that all individual layers are applied using an inkjet printing process.

[0023] The layer may be arranged on the inside of the cover element. "Inside" here refers to the inner side opposite the intended visible side of the cover element. The layer is therefore oriented towards the device for transmitting and / or receiving electromagnetic waves.

[0024] It may be provided that at least one protective coating, in particular a silane coating, is arranged on the visible side of the cover element.

[0025] The device may be a LIDAR device (LIDAR = Light Detection and Ranging). In this case, the LIDAR device uses light in the form of a pulsed laser to detect and categorize objects. RESRG Automotive SE & Co. KG Rehau, March 27, 2025 Int. Ref: 24.097 / 2 dr.lauk

[0026] The exterior trim component may be a bumper cover, fender cover, rocker panel cover, spoiler, door panel, or, in particular, a front panel. A front panel is the part of a vehicle where the radiator grille was located in combustion engine vehicles. Especially in electric vehicles, this front panel is no longer designed as an air intake for the radiator (which is no longer present), but rather as a design element in the center of the vehicle.

[0027] A method according to the invention for manufacturing an exterior panel part of a vehicle, in particular an exterior panel part as described above, with a thin-walled cover element for covering and protecting a device for transmitting and / or receiving electromagnetic waves from environmental influences,

[0028] wherein the cover element has a designated visible side and an inner side opposite the visible side and is configured in such a way that it can be penetrated by electromagnetic waves of at least one wavelength in the range of 100 nm to 1600 nm,

[0029] the cover element further comprises:

[0030] at least one carrier layer made of a polymer material that is transparent or partially transparent to electromagnetic waves,

[0031] at least one layer of an antireflection coating and / or antireflection structuring designed to reduce the reflection of the intended electromagnetic waves at the cover element, wherein the layer is arranged at least on the area of ​​the substrate layer to be penetrated by the electromagnetic waves (and limited to this area), wherein the layer of the antireflection coating and / or antireflection structuring is composed of at least two individual layers arranged one above the other,

[0032] wherein the wall thickness of the cover element is in a range of 1 mm to 8 mm, preferably in the range of 1.5 mm to 5 mm, and

[0033] the procedure has the following sequence of steps: RESRG Automotive SE & Co. KG Rehau, March 27, 2025 Int. Ref: 24.097 / 2 dr.lauk

[0034] Providing a carrier layer,

[0035] - Applying a first single layer to the substrate, wherein the refractive index of the first single layer arranged on the substrate has a lower refractive index than the refractive index of the polymer material of the substrate,

[0036] - Applying a second single layer to the first single layer, wherein the refractive index of the second single layer arranged above the first single layer is lower than the refractive index of the first single layer.

[0037] It may be provided that the first single layer and the second single layer are applied using an inkjet printing process.

[0038] It may be provided that the supporting structure is supplied by means of an injection molding process in an injection molding tool.

[0039] It may be provided that the first single layer and the second single layer are applied using an inkjet printing process, and that the provision of the supporting structure is carried out using an injection molding process in an injection molding tool, and that the application of the single layers to the supporting structure takes place while the supporting structure is still in the open or partially open injection molding tool.

[0040] The polymer material of the support layer may preferably include polycarbonate, polymethyl methacrylate, polystyrene, thermoplastic polyester, polypropylene or a biopolymer.

[0041] The invention is explained in more detail with reference to figures illustrating only exemplary embodiments. Identical or functionally equivalent elements are designated with the same reference numerals.

[0042] Shown by: RESRG Automotive SE & Co. KG Rehau, March 27, 2025 Int. Ref: 24.097 / 2 dr.lauk

[0043] Fig. 1: an exterior cladding part in the form of a front panel in a front view;

[0044] Fig. 2: an exterior cladding part in the form of a front panel in a rear view;

[0045] Fig. 3-4: two cross-sections through the area to be irradiated of two variants of the outer cladding part;

[0046] Fig. 5: a schematic representation of a partial step of the process for manufacturing the outer cladding part.

[0047] Figures 1 and 2 each show an exterior panel 1 of a vehicle in the form of a front panel, with a thin-walled cover element 2 for covering and protecting a device 3 for transmitting and / or receiving electromagnetic waves (see Figure 3 or Figure 4) from environmental influences.

[0048] wherein the cover element 2 has a designated visible side A and an inner side B opposite the visible side A and is configured such that it can be penetrated by electromagnetic waves of at least one electromagnetic wavelength in the range of 100 nm to 1600 nm,

[0049] the cover element 2 further comprises (see Fig. 3 or Fig. 4):

[0050] at least one carrier layer 4 made of a polymer material that is transparent or partially transparent to electromagnetic waves,

[0051] At least one layer 5 of an anti-reflective coating and / or anti-reflective structuring, designed to reduce the reflection of the intended electromagnetic waves at the cover element 2, wherein the layer 5 is arranged at least on the area X of the carrier layer 4 to be traversed by the electromagnetic waves, wherein the wall thickness, measured in cross-section, of the cover element 2 is in the range of 1 mm to 8 mm, preferably in the range of 1.5 mm to 5 mm. RESRG Automotive SE & Co. KG Rehau, March 27, 2025 Int. Ref: 24.097 / 2 dr.lauk

[0052] Figure 3 shows that the layer 5 of the antireflection coating and / or antireflection structuring is composed of at least two superimposed individual layers 6, 7, wherein the refractive index of the first individual layer 6 arranged on the carrier layer 4 has a lower refractive index than the refractive index of the polymer material of the carrier layer 4, and that the refractive index of the second individual layer 7 arranged above the first individual layer 6 is lower than the refractive index of the first individual layer 6.

[0053] As a variant of this, it can be seen in Fig. 4 that the layer 5 of the antireflection coating and / or antireflection structuring is made up of at least three individual layers 6, 7, 8 arranged one above the other, wherein the refractive index of the third individual layer 8 arranged above the second individual layer 7 is lower than the refractive index of the second individual layer 8.

[0054] At least one of the individual layers 6, 7, 8 of layer 5 is applied using an inkjet printing process. In this case, all individual layers 6, 7, 8 are applied using an inkjet printing process.

[0055] Layer 5 is located on the inside B of the cover element 2.

[0056] On the visible side A of the cover element 2, at least one protective coating 9, in particular a silane coating, is arranged.

[0057] Figure 5 describes in more detail the manufacturing process according to the invention for an outer cladding part:

[0058] Method for manufacturing an exterior trim part 1 of a vehicle, in particular an exterior trim part as described above, with a thin-walled cover element 2 for covering and protecting a device 3 for transmitting and / or receiving electromagnetic waves from environmental influences,

[0059] wherein the cover element 2 has a designated visible side A and an inner side B opposite the visible side A and is configured such that it can be penetrated by electromagnetic waves of at least one wavelength in the range of 100 nm to 1600 nm, RESRG Automotive SE & Co. KG Rehau, March 27, 2025 Int. Ref: 24.097 / 2 dr.lauk

[0060] the cover element 2 further comprises:

[0061] at least one carrier layer 4 made of a polymer material that is transparent or partially transparent to electromagnetic waves,

[0062] at least one layer 5 of an antireflection coating and / or antireflection structuring designed to reduce the reflection of the intended electromagnetic waves at the cover element 2, wherein the layer 5 is arranged at least on the area X of the carrier layer 4 to be traversed by the electromagnetic waves, wherein the layer 5 of the antireflection coating and / or antireflection structuring is composed of at least two superimposed individual layers 6, 7,

[0063] wherein the wall thickness of the cover element 2 is in a range of 1 mm to 8 mm, preferably in the range of 1.5 mm to 5 mm, and wherein the method comprises the following sequence of steps:

[0064] Providing a carrier layer 4,

[0065] - Applying a first single layer 6 to the support layer 4, wherein the refractive index of the first single layer 6 arranged on the support layer 4 has a lower refractive index than the refractive index of the polymer material of the support layer 4,

[0066] - Applying a second single layer 7 to the first single layer 6, wherein the refractive index of the second single layer 7 arranged above the first single layer 6 is lower than the refractive index of the first single layer 6.

[0067] The first single layer 6 and the second single layer 7 are applied using an inkjet printing process. Figure 5 shows that a printhead (11) is guided over the carrier layer 4 (for example, by means of a robot or a traversing unit).

[0068] In this embodiment, the supporting structure 3 is provided by means of an injection molding process in an injection mold 10, wherein the application of the RESRG Automotive SE & Co. KG Rehau, March 27, 2025 Int. Ref: 24.097 / 2 dr.lauk

[0069] Individual layers 6, 7 are applied to the support structure 3 while the support structure 3 is still in the open or partially open injection mold 10.

Claims

RESRG Automotive SE & Co. KG Rehau, March 27, 2025 Int. Ref: 24.097 / 2 lauk Patent claims 1. Exterior cladding part (1) of a vehicle, comprising a thin-walled cover element (2) for covering and protecting a device (3) for transmitting and / or receiving electromagnetic waves from environmental influences, wherein the cover element (2) has a designated visible side (A) and an inner side (B) opposite the visible side (A) and is configured such that it can be penetrated by electromagnetic waves of at least one electromagnetic wavelength in the range of 100 nm to 1600 nm, the cover element (2) further comprises: - at least one carrier layer (4) made of a polymer material that is transparent or partially transparent to electromagnetic waves, - at least one layer (5) of an antireflection coating and / or antireflection structuring designed to reduce the reflection of the intended electromagnetic waves at the cover element (2), wherein the layer (5) is arranged at least on the area (X) of the carrier layer (4) to be traversed by the electromagnetic waves, wherein the wall thickness of the cover element (2) is in a range of 1 mm to 8 mm, preferably in the range of 1.5 mm to 5 mm, characterized by the fact that The layer (5) of the antireflection coating and / or antireflection structuring is composed of at least two superimposed individual layers (6, 7), wherein the refractive index of the first individual layer (6) arranged on the substrate layer (4) has a lower refractive index than the refractive index of the polymer material of the substrate layer (4), and wherein the refractive index of the second individual layer (7) arranged above the first individual layer (6) is lower than the refractive index of the first individual layer (6). RESRG Automotive SE & Co. KG Rehau, March 27, 2025 Int. Ref: 24.097 / 2 lauk 2. Outer cladding part (1) according to claim 1, characterized in that the layer (5) of the antireflection coating and / or antireflection structuring is composed of at least three individual layers (6, 7, 8) arranged one above the other, wherein the refractive index of the third individual layer (8) arranged above the second individual layer (7) is lower than the refractive index of the second individual layer (8).

3. Outer cladding part (1) according to one of the preceding claims, characterized in that at least one of the individual layers (6, 7, 8) of the layer (5) is applied by means of an inkjet printing process.

4. Outer cladding part (1) according to claim 3, characterized in that all individual layers (6, 7, 8) are applied by means of an inkjet printing process.

5. Outer cladding part (1) according to one of the preceding claims, characterized in that the layer (5) is arranged on the inside (B) of the cover element (2).

6. Outer cladding part (1) according to one of the preceding claims, characterized in that at least one protective coating (9), in particular a silane coating, is arranged on the visible side (A) of the cover element (2).

7. Method for manufacturing an exterior trim part (1) of a vehicle, in particular an exterior trim part according to one of claims 1 to 6, comprising a thin-walled cover element (2) for covering and protecting a device (3) for transmitting and / or receiving electromagnetic waves from environmental influences, wherein the cover element (2) has a designated visible side (A) and an inner side (B) opposite the visible side (A) and is configured to be penetrated by electromagnetic waves of at least one wavelength in the range of 100 nm to 1600 nm, the cover element (2) further comprises: RESRG Automotive SE & Co. KG Rehau, March 27, 2025 Int. Ref: 24.097 / 2 lauk - at least one carrier layer (4) made of a polymer material that is transparent or partially transparent to electromagnetic waves, - at least one layer (5) of an antireflection coating and / or antireflection structuring designed to reduce the reflection of the intended electromagnetic waves at the cover element (2), wherein the layer (5) is arranged at least on the area (X) of the carrier layer (4) to be traversed by the electromagnetic waves, wherein the layer (5) of the antireflection coating and / or antireflection structuring is composed of at least two superimposed individual layers (6, 7), wherein the wall thickness of the cover element (2) is in a range of 1 mm to 8 mm, preferably in the range of 1.5 mm to 5 mm, and the procedure has the following sequence of steps: Providing a carrier layer (4), - Applying a first single layer (6) to the support layer (4), wherein the refractive index of the first single layer (6) arranged on the support layer (4) has a lower refractive index than the refractive index of the polymer material of the support layer (4), - Applying a second single layer (7) to the first single layer (6), wherein the refractive index of the second single layer (7) arranged above the first single layer (6) is lower than the refractive index of the first single layer (6).

8. Method according to claim 7, characterized in that the first single layer (6) and the second single layer (7) are applied by means of an inkjet printing process.

9. Method according to one of the preceding claims 7 or 8, characterized in that the provision of the support structure (3) is carried out by means of an injection molding process in an injection mold (10). RESRG Automotive SE & Co. KG Rehau, March 27, 2025 Int. Ref: 24.097 / 2 lauk 10. Method according to claims 8 and 9, characterized in that the application of the individual layers (6, 7) to the support structure (3) takes place while the support structure (3) is still in the open or partially open injection mold (10).

Images