CONTROL UNIT FOR A VEHICLE INTERIOR AND METHOD FOR PRODUCING THE CONTROL UNIT

Abstract

The present disclosure relates to a control unit for a vehicle interior. In particular, the control unit can comprise an information region with symbols, wherein some symbols are always visible and some symbols are only visible when they are back lit. The application also relates to a method for producing a corresponding control unit. The control unit can be part of a vehicle interior trim part, for example part of an instrument panel, door trim or center console.

Claims

1. A control unit for a vehicle interior comprising: a transparent cover layer; an opaque mask layer; and a translucent decorative layer arranged between the cover layer and the mask layer; wherein the mask layer and the decorative layer each have at least one through-hole in a first region, wherein in the first region the at least one through-hole of the mask layer and the at least one through-hole of the decorative layer are aligned with each other, and wherein, in a second region, the mask layer has at least one through-hole which is covered by the decorative layer.

2. The control unit according to claim 1, wherein, in a third region, the mask layer has a plurality of through-holes, wherein the decorative layer covers at least one through hole of the plurality of through holes, and wherein the third region surrounds the first region and the second region.

3. The control unit according to claim 1, wherein, in the first region, at least one of the at least one through-hole of the mask layer or the at least one through-hole of the decorative layer is formed and arranged in such a way that at least one symbol is visible on a visible side of the control unit.

4. The control unit according to claim 1, wherein, in the second region, the at least one through-hole of the mask layer is formed and arranged in such a way that at least one symbol is visible on a visible side of the control unit when the control unit is back lit.

5. The control unit according to claim 2, wherein at least one of the at least one through-hole of the mask layer in the first region or the at least one-through-hole of the mask layer in the second region is formed by laser erosion, and/or wherein, in the third region, at least one through-hole of the plurality of through-holes in the mask layer is formed by screen printing.

6. The control unit according to claim 1, wherein the transparent cover layer comprises at least one of a foil layer, a carrier layer, or a protective layer.

7. The control unit according to claim 1, wherein the decorative layer comprises at least one of a metal layer or a tinted color layer.

8. The control unit according to claim 2, wherein at least one further translucent layer is arranged in at least one of the second region or the third region between the decorative layer and the mask layer.

9. The control unit according to claim 4, wherein at least one of a light-permeable diffusor layer or a protective layer is arranged on a rear side of the mask layer, and wherein the rear side faces away from the visible side.

10. A method for producing a control unit for a vehicle, the method comprising: providing a first foil having a front side and a rear side; printing a translucent decorative layer onto the rear side of the foil; printing on at least a portion of an opaque mask layer; eroding at least a portion of the opaque mask layer; forming at least one through-hole in a first region of the opaque mask layer; forming at least one through-hole in a second region of the opaque mask layer; and eroding at least a portion of the translucent decorative layer by laser erosion, to form at least one through-hole in the decorative layer that corresponds to the at least one through hole in the first region of the opaque mask layer.

11. The method according to claim 10, wherein the printing of the translucent decorative layer is done by screen printing.

12. The method according to claim 10, wherein the printing on the at least a portion of the opaque mask layer is done by screen printing.

13. The method according to claim 10, wherein the eroding of the at least a portion of the opaque mask layer is done using laser erosion.

14. The method according to claim 10, wherein the at least one of the at least one through-hole in the first region of the opaque mask layer or the at least one through hole in the second region of the opaque mask layer is formed using a laser.

15. The method according to claim 10, wherein the opaque mask layer is applied across the entire first region, applied across the entire second region, applied in a portion of a third region, so that the mask layer has on or more through-holes in the third region.

16. The method according to claim 10, wherein a diffusor layer is printed in the first region on a side of the opaque mask layer facing away from a visible side by pad printing.

17. The method according to claim 16, wherein a protective layer is applied on at least one of: a side of the opaque mask layer in at least one of the first region of the opaque mask layer, the second region of the opaque mask layer, or third region of the of the opaque mask layer, the side of the opaque mask layer facing away from the visible side or a side of the diffusor layer facing away from the visible side, wherein the protective layer is applied by pad printing.

18. A control unit for a vehicle interior comprising: a transparent cover layer; an opaque mask layer; and a translucent decorative layer arranged between the cover layer and the mask layer; wherein the mask layer and the decorative layer each have at least one through-hole in a first region, wherein in the first region the at least one through-hole of the mask layer and the at least one through-hole of the decorative layer are aligned with each other, and wherein, in a second region, the mask layer has at least one through-hole which is covered by the decorative layer, wherein, in a third region, the mask layer has a plurality of through-holes, wherein the decorative layer covers at least one through hole of the plurality of through holes, and wherein the third region surrounds the first region and the second region, wherein, in the first region, at least one of the at least one through-hole of the mask layer or the at least one through-hole of the decorative layer is formed and arranged in such a way that at least one symbol is visible on a visible side of the control unit, and wherein, in the second region, the at least one through-hole of the mask layer is formed and arranged in such a way that at least one symbol is visible on a visible side of the control unit when the control unit is back lit.

19. The control unit according to claim 18, wherein at least one of the at least one through-hole of the mask layer in the first region or the at least one-through-hole of the mask layer in the second region is formed by laser erosion, and/or wherein, in the third region, at least one through-hole of the plurality of through-holes in the mask layer is formed by screen printing.

20. The control unit according to claim 18, wherein the transparent cover layer comprises at least one of a foil layer, a carrier layer, or a protective layer, wherein the transparent cover layer comprises at least one of a foil layer, a carrier layer, or a protective layer, wherein at least one further translucent layer is arranged in at least one of the second region or the third region between the decorative layer and the mask layer, wherein at least one of a light-permeable diffusor layer or a protective layer is arranged on a rear side of the mask layer, and wherein the rear side faces away from the visible side.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0065] In the figures

[0066] FIG. 1 shows a schematic description of a control unit with a first, a second, and a third region, in a plan view and a schematic sectional view of the three region of the control unit.

[0067] FIG. 2 shows a schematic sectional view of the three regions of the control unit of FIG. 1, and a sectional view of the control unit.

[0068] FIG. 3 shows a perspective view of a control unit,

[0069] FIG. 4 shows a sectional view through regions of the control unit of FIG. 3,

[0070] FIG. 5 shows a perspective view of the control unit of FIG. 3 with switched-off illuminants, and

[0071] FIG. 6 shows an illustration of an exemplary production process of a control unit according to FIG. 4 or 5.

DETAILED DESCRIPTION

[0072] FIG. 1 (a) shows a schematic depiction of a control unit on a visible side A in a plan view. The control unit has a layered structure, as can be seen in a cross-sectional illustration of FIG. 1 (b). The control unit has a mask layer 2, on which there is arranged a decorative layer 3. A cover layer 1 is in turn arranged on the decorative layer 3. The decorative layer 3 is thus arranged between the cover layer 1 and the mask layer 2.

[0073] The control unit also has a rear side B. When the control unit is arranged in a vehicle interior, the visible side A points toward the vehicle interior, whereas the rear side B is not visible to a vehicle occupant.

[0074] Tye control unit has a first region I, a second region II and a third region III. In the first region I there is arranged a symbol i, which is permanently visible from the visible side. The symbol is formed by through-holes 31 in the decorative layer 3 and through-holes 21 in the mask layer 2. The through-holes 31 and 21 are arranged one above the other and aligned with each other and covered by the cover layer 1. The cover layer 1 is transparent, whereas the decorative layer 3 is translucent and the mask layer 2 is opaque.

[0075] In the second region II there is arranged a symbol ii, which is only visible from the visible side when the symbol is back lit. If it is not back lit, it is not visible from the visible side. The symbol ii is formed by through-holes 22 in the mask layer 2. These through-holes 22 are covered by the decorative layer 3 so that the contours of the through-holes 22 are not visible when no illuminant on the rear side B of the control unit in the region of the symbol ii is switched on.

[0076] The symbol i or symbol ii can be back lit by an illuminant, for example an LED or an electroluminescence foil, which is arranged on the rear side B of the control unit. At least one illuminant is preferably provided for each symbol i or ii. The illuminants can be switched on and off independently of one another. The symbol i shows a triangle with an exclamation mark therein and is, for example, the symbol of a hazard warning light in a vehicle. When the hazard warning light is switched on, the symbol i is back lit. If the hazard warning light is switched off, the illuminant behind the symbol i is switched off again. Nevertheless, the contour of the symbol can be seen from the visible side.

[0077] The symbol ii shows a headlight. If the dipped beam of a vehicle is switched on, the symbol ii is back lit and is visible. If the dipped beam is not switched on, the symbol is not back lit and is not visible from the visible side.

[0078] The third region III is characterized in that an ambient light is adjustable. The mask layer 2 of the third region III has through-holes 23 which can also be back lit by illuminants. A decorative layer 3″ is arranged between the mask layer 2 and the cover layer 1. The decorative layer 3″ preferably corresponds to the decorative layer 3′ in the first region I and second region II. In some exemplary embodiments the properties and characteristics of the decorative layer 3′ and 3″ differ. For example, another color, a different translucency or a different surface appearance or a different material can be selected. For example, the decorative later of the third region can be more permeable to light than the decorative layer 3′ of the first region I and second region II. When the third region III is back lit, an indirect light is emitted at the visible side. The light passes through the decorative layer 3″ and is scattered. For example, a vehicle interior can thus be illuminated indirectly.

[0079] FIG. 2 shows a control element which corresponds substantially to the control element of FIG. 1. The control unit is shown schematically in FIG. 2 (a) and in a plan view. In FIG. 2 (b) the control unit is shown in a sectional view along the line of section AA shown in FIG. 2 (a). It is shown in FIG. 2 (b) that the mask layer 2, the decorative layer 3 and the cover layer 1 have the same material thickness and each extend over the entire control unit. Material cut-outs are provided in the region of the above-described through-holes 21, 22, 23. The regions I and II transition fluently into one another and the changes between regions are not visible from the visible side. To this end, the decorative layer 3′ in regions I and II are the same, whereas the decorative layer 3″ differs from the decorative layer in regions I and II. For example, the decorative layer 3″ has a higher translucency. For example, the region III, which displays a lighting function, can be optically separated from regions I and II, which serve as information regions. The third region III surrounds the first region and the second regions I, II. For example, the information of the first and second regions I, II can be highlighted again and an eye of a vehicle occupant can be drawn to these regions I, II and the symbols i, ii, which are partly safety-relevant and are located in said regions.

[0080] The cover layer 1 of FIGS. 1 and 2 comprises polycarbonate and is transparent. The decorative layer 3′ is made of aluminum and is applied to the decorative layer 1 by physical vapor deposition. The decorative layer 3′ is made of tin and is applied to the decorative layer 1 by physical vapor deposition. The mask layer 2 comprises the substance mixtures, conventional for screen printing, of dyes, solvents and binders which are applied as emulsion, dispersion or plastisol. The polymer base can comprise polyurethane, polyester, acrylic or acrylate. The mask layer 2 is printed onto the decorative layer 3 by means of screen printing. The mask layer 2 is applied to the decorative layer 3′ in the first and second region across the whole area, whereas the mask layer 2 is printed onto the decorative layer 3″ with cut-outs so that the mask layer 2 has through-openings in the third region. The mask layer 2 can be eroded by laser. In the first region I, the mask layer 2 has been eroded in some regions using a laser so that through-holes 21 are created. Furthermore, the decorative layer 3′ in the first region has been eroded in the region of the through-holes 21 so that through-holes 31 have been generated in the decorative layer 3′. In the second region, the mask layer has been eroded in some regions in order to generate through-holes 22, which are covered by the decorative layer 3′.

[0081] FIG. 3 shows a perspective view of a control unit. The control unit is part of a vehicle interior trim part. The structure of the control unit corresponds substantially to the structure of the control unit of the previous figures. An information region (comprising regions I and regions II) is shown, in which three permanently visible symbols i are shown: a symbol which indicates door locking, a symbol which indicates door unlocking, and a symbol which indicates whether an warning hazard light is activated. Furthermore, symbols ii are shown in the information region which are only visible when they are back lit. These symbols ii are, for example, the signs for a switched-on dipped beam, for a fuel level indicator or a reserve tank light. The information region of FIG. 3 corresponds to a combination of the regions I and II shown in FIGS. 1 and 2. The control unit comprises illuminants which are arranged behind the symbols. A lighting element is arranged behind each symbol i, or ii. Each lighting element is controllable independently of the further lighting elements. The lighting elements are assigned to functions, so that, for example, the lighting element arranged behind the symbol i, which is designed in the form of a warning hazard light warning sign, lights up when the warning hazard light is switched on.

[0082] The permanently visible symbols i are permanently visible, because, as described in greater detail with reference to FIGS. 1 and 2, the through-holes 21 in the mask layer 2 are not covered by the decorative layer 3, and instead corresponding through-holes 31 are provided in the decorative layer.

[0083] The symbols ii that disappear when the lighting elements are switched off are not permanently visible, because, as described in greater detail with reference to FIGS. 1 and 2, the through-holes 21 in the mask layer 2 are covered by the decorative layer 3. In FIG. 3 the lighting elements behind the symbols ii are switched on so that the symbols ii are visible.

[0084] The regions I, II of the control unit are surrounded by a region III, which corresponds to the region III described in FIGS. 1 and 2.

[0085] FIG. 4 shows a sectional view through the regions I, II, III of a control unit according to one of the previous figures. FIG. 4 (a) shows the third region, FIG. 4 (b) shows the second region II, and FIG. 4 (c) shows the first region I. The front side, i.e., the visible side of the control unit, is denoted by “A”, and the rear side of the control unit is denoted by “B”.

[0086] All three regions have a cover layer 1. This cover layer 1 comprises three layers: a foil layer 11, a carrier layer 12 and a protective layer 13. The protective layer 13 is a PU clear lacquer, 0.6 mm, applied by means of the reaction injection molding (RIM) method. The protective layer offers protection against scratches and allows small radii. The carrier layer 12 is a transparent polycarbonate film (IML/FIM) so as to allow a rigidity of the parts. A glass-like appearance is also generated in this way. An optical depth effect is achieved by the thickness of the carrier layer of 10 mm. The foil layer 11 is a PC film with a thickness of 0.5 mm, which serves as a carrier and protection for the decoration components (tinted layer, layer with metallic appearance, screen-printed layers). The PC foil is suitable in particular for the thermoforming method and the IML/FIM process, so that a deformation of the component can take place in this way. In addition, an adhesion promoter layer can be applied in order to ensure the adhesion in IML/FIM.

[0087] The decorative layer 3 is arranged below the cover layer 1. The decorative layer comprises a metal layer 301 and/or a tinted color layer 302. The tinted color layer 302 is arranged between the metal layer 301 and the cover layer 1. The tinted color layer 302 is semi-transparent and offers a “dark chrome” effect. The tinted color layer can be tinted in different colors, in the present case for example in a dark blue. The tinted color layer 302 is laser-engraved in the first region so that it has through-holes 31 in order to allow ever-visible symbols in the region I.

[0088] The metal layer 301 is a metal-like layer, with low electrical conductivity, in order to be compatible with capacitive contact sensors. The metal layer 301 is semi-transparent in order to ensure a metallic appearance when it is not back lit. With backlighting, the metal layer 301 allows light to pass through in order to allow visible symbols. The metal layer is made of chromium and applied by means of PVD to the tinted color layer 302.

[0089] In the third region III and in the second region II, a translucent layer 42 is also arranged between the mask layer 2 and the metal layer 301. The translucent layer 42 is a dark, semi-transparent layer which is applied to the metal layer 301 by means of screen printing in order to reduce the contrast (in particular the visibility of the transition) between the opaque mask layer and the translucent decorative layer. In the second region, below the translucent layer 42, there is also arranged a further translucent layer 41. This has a light color and is semi-transparent. The translucent layer 41 serves in particular to protect the metal layer during the laser erosion of the mask layer 2 to generate the through-holes 22. Furthermore, the translucent layer can cause a scattering of the background lighting.

[0090] In all three regions I, II, III, the mask layer 2 is arranged beneath the decorative layer 3: in region I directly beneath the decorative layer 3, in region II adjacently to the translucent layer 41, and in region III adjacently to the translucent layer 42. The mask layer 2 is printed by means of screen printing onto the layer arranged thereabove correspondingly. The mask layer 2, in regions I and II, has through-holes 21, 22, which have been engraved into the mask layer 2 by means of laser erosion. In the third region the through-holes 23 were cut out during the screen printing.

[0091] In the second region a transparent or semi-transparent protective layer 5 for protecting the lasered edges and for protecting the metal layer 301 against ambient influences (in particular moisture, acids, oxygen) is arranged directly beneath the mask layer 2.

[0092] In the first region, a diffusor layer 6 is arranged directly beneath the mask layer 2. Said diffusor layer is pad printed and, for example, red or white in order to obtain a different color of the ever-visible symbols (here for example red for hazard warning light and white for door locking/unlocking).

[0093] The control unit also comprises capacitive sensors in order to allow an activation and/or adjustment by touching the surface A. The sensor system is not shown.

[0094] FIG. 5 shows the control unit of FIG. 4 in a state in which the illuminates are switched off. The disappearing symbols ii are not visible, whereas the permanently visible symbols i are visible.

[0095] In FIG. 6, a process for producing a control unit as per the previous figures, in particular FIG. 3 or 5, is shown. Reference is made to the above description in respect of FIGS. 3 to 5. The foil layer 11 is provided in accordance with the above description and is printed with the tinted color layer 301 and with the metal layer 302, as shown in FIG. 6 (a). At this point of the method, the layered structure of the control unit is the same in all regions I-III. The printed foil is then trimmed into a desired shape. In a next method step (shown in FIG. 6 (b)), the translucent layer 42 in the second region and in the third region is printed onto a rear side of the metal layer 301 facing away from the cover layer. In the second region, the translucent layer 41 is printed onto a side of the translucent layer 42 facing away from the cover layer 1. The mask layer 2 is printed onto a rear side of the translucent layer 42 in the third region III onto a rear side of the translucent layer 41 in the second region II and onto a rear side of the metal layer 301 in the first region I. In the third region, cut-outs are provided so that through-holes 23 are created, whereas the mask layer is applied over the entire area in the first and in the second region I, II.

[0096] In a next method step (FIG. 6 (c)), the component can be per-shaped, for example under the action of heat or in a high-pressure method.

[0097] The per-shaped form can be fixed in a next method step (FIG. 6 (d)). For this purpose, a carrier layer 12 made of liquid plastic is sprayed onto a front side of the foil layer 11, preferably by means of FIM or IML, and cures so that the above-described carrier layer 12 is created. In a next method step (FIG. 6 (e)), a protective layer 13 can be applied to a front side of the carrier layer 11, preferably sprayed on, or can be applied by means of dipping. Through-holes 21, 22 are then removed from the mask layer 2 in the second region II (FIG. 6 (f)) and in the first region I (FIG. 6 (g)) using a laser. In the first region I, through-holes 31 are also generated in the metal layer 301 and in the tinted color layer 302 via laser erosion. In the next method step, the diffusor layer 6 is applied in the first region I to a rear side B of the mask layer 2, in particular also into the through-holes 21, by means of pad printing (FIG. 6 (h)). In the last step (FIG. 6 (i)), a protective layer 5 is applied to the rear side of the mask layer 2, covering the through-holes 22, by means of pad printing.