MOLDING HAVING A TRANSLUCENT SURFACE LAYER AND METHOD FOR PRODUCING A MOLDING HAVING A TRANSLUCENT SURFACE LAYER

Abstract

Disclosed is a molding having a translucent surface layer and to a method for producing a molding that has a translucent surface layer.

Claims

1: A molding with a transilluminable surface layer at a visible side, comprising a functional film having at least one transilluminable region, a surface layer applied to the functional film on the visible side of the molding, wherein the surface layer is formed by a textile, leather, imitation leather, wood veneer or wood laminate or from a metal foil, a transilluminable layer injection-molded on the rear side of the functional layer and serving as a diffusing pane for incident light, wherein the rear side of the functional layer forms the side opposite the surface layer, and wherein lateral shielding of the transilluminable layer by bent-over regions of the functional film and the surface layer is realised, wherein a light barrier preventing lateral issue of light is provided by the thus-formed edge fold and wherein an optical conductor into which light can be introduced by way of a light source is arranged at the lower side of the transilluminable layer so that the transilluminable layer formed as a diffusing pane is illuminated over the whole area by way of the optical conductor for illumination of the at least one illuminatable region.

2: A molding with a transilluminable surface layer at a visible side, comprising a functional film having a reflective structure and at least one light source, wherein the reflective structure through laterally introduced radiation by the at least one light source produces irradiation at the visible side of the molding, the at least one light source is integrated in the functional film, a carrier layer of plastics material injection-molded on the rear side of the functional film, wherein the rear side of the functional film forms the side opposite the visible side of the molding, an at least regionally transilluminable surface layer disposed on the visible side of the molding, wherein the surface layer is formed by a textile, leather, imitation leather, wood veneer or wood laminate or from a metal foil, a transilluminable connecting layer arranged between the functional film and the surface layer and connected by a chemical connection and/or a mechanically positive connection with both the functional film and the surface layer, and wherein lateral shielding of the transilluminable connecting layer is realised by bent-over regions of the surface layer and the edge fold realised by the bent-over regions is held by a third plastics material which is injection-molded at the lower side of the functional film at the bent-over regions.

3: The molding according to claim 1, wherein the functional film comprises at least one functional element for operating and/or controlling at least one component connectible by way of signal connection with the functional film and the at least one functional element.

4: The method for producing a molding according to claim 1, with a transilluminable surface layer at a visible side, in a one-shot process without subsequent processes, comprising the following method steps: providing a functional film and an at least partly transilluminable surface layer, wherein the surface layer is formed by a textile, leather, imitation leather, wood veneer or wood laminate or from a metal foil, connecting the surface layer with the functional film, back-molding the functional film with a transilluminable plastics material in an injection-molding process, wherein the transilluminable plastics material is applied to the functional film and at least one side has an at least regionally smaller dimension than the functional film and bending over the projecting part of the functional film.

5: The method according to claim 4, wherein connecting the surface layer with the functional film is carried out prior to or after back-molding the functional film.

6: The method according to claim 4, wherein the surface layer completely covers the area of the functional film on the visible side.

7: The method of producing a molding according to claim 2, with a transilluminable surface layer at a visible side, in a multi-component injection-molding method in a one-shot process without subsequent processes, comprising the following method steps: inserting a functional film into a cavity of a mold half of an injection-molding tool, wherein the functional film has a reflective structure and at least one light source, back-molding the functional film in the injection-molding tool with a first plastics material for formation of a carrier layer for the functional film, transferring the first intermediate product formed from the functional film and the carrier layer into a second cavity of the injection-molding tool, introducing an at least regionally transilluminable surface layer into the second cavity, wherein the surface layer has a larger area dimension than the first intermediate product consisting of the functional film and carrier layer and wherein the surface layer is formed by a textile, leather, imitation leather, wood veneer or wood laminate or from a metal foil, injection-molding a second plastics material between the first intermediate product and the surface layer, wherein the second plastics material connects with the surface layer and the functional film, bending over projecting regions of the surface layer, transferring the second intermediate product consisting of the functional film, carrier layer, surface layer and second plastics material into a further cavity and over-molding the bent-over regions of the surface layer with a third plastics material at the rear side of the functional film, wherein the rear side is opposite the visible side of the molding.

8: The method according to claim 7, wherein a transparent or translucent plastics material is used for the second plastics material.

9: The method according to claim 7, wherein the edge fold is fixed by the third plastics material consisting of a soft component.

10: The method according to claim 7, wherein bending-over of the projecting regions of the surface layer is carried out in a third cavity or by way of pushers in the injection-molding tool.

11: The molding according to claim 2, wherein the functional film comprises at least one functional element for operating and/or controlling at least one component connectible by way of signal connection with the functional film and the at least one functional element.

12: The method for producing a molding according to claim 3, with a transilluminable surface layer at a visible side, in a one-shot process without subsequent processes, comprising the following method steps: providing a functional film and an at least partly transilluminable surface layer, wherein the surface layer is formed by a textile, leather, imitation leather, wood veneer or wood laminate or from a metal foil, connecting the surface layer with the functional film, back-molding the functional film with a transilluminable plastics material in an injection-molding process, wherein the transilluminable plastics material is applied to the functional film and at least one side has an at least regionally smaller dimension than the functional film and bending over the projecting part of the functional film.

13: The method according to claim 12, wherein connecting the surface layer with the functional film is carried out prior to or after back-molding the functional film.

14: The method according to claim 5, wherein the surface layer completely covers the area of the functional film on the visible side.

15: The method of producing a molding according to claim 3, with a transilluminable surface layer at a visible side, in a multi-component injection-molding method in a one-shot process without subsequent processes, comprising the following method steps: inserting a functional film into a cavity of a mold half of an injection-molding tool, wherein the functional film has a reflective structure and at least one light source, back-molding the functional film in the injection-molding tool with a first plastics material for formation of a carrier layer for the functional film, transferring the first intermediate product formed from the functional film and the carrier layer into a second cavity of the injection-molding tool, introducing an at least regionally transilluminable surface layer into the second cavity, wherein the surface layer has a larger area dimension than the first intermediate product consisting of the functional film and carrier layer and wherein the surface layer is formed by a textile, leather, imitation leather, wood veneer or wood laminate or from a metal foil, injection-molding a second plastics material between the first intermediate product and the surface layer, wherein the second plastics material connects with the surface layer and the functional film, bending over projecting regions of the surface layer, transferring the second intermediate product consisting of the functional film, carrier layer, surface layer and second plastics material into a further cavity and over-molding the bent-over regions of the surface layer with a third plastics material at the rear side of the functional film, wherein the rear side is opposite the visible side of the molding.

16: The method according to claim 15, wherein a transparent or translucent plastics material is used for the second plastics material.

17: The method according to claim 8, wherein the edge fold is fixed by the third plastics material consisting of a soft component.

18: The method according to claim 8, wherein bending-over of the projecting regions of the surface layer is carried out in a third cavity or by way of pushers in the injection-molding tool.

19: The method according to claim 9, wherein bending-over of the projecting regions of the surface layer is carried out in a third cavity or by way of pushers in the injection-molding tool.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0063] In the drawings:

[0064] FIG. 1 shows a schematic illustration of a molding in a first form of embodiment;

[0065] FIGS. 2a)-e) shows different states of the molding according to FIG. 1 during production;

[0066] FIG. 3 shows a schematic illustration of a molding in a second form of embodiment; and FIGS. 4a)-d) shows different states of the molding according to FIG. 3 during production.

[0067] Elements provided in the drawings with the same reference numerals substantially correspond with one another insofar as nothing to the contrary is indicated. In addition, illustration and description of components not essential to understanding the technical teaching disclosed herein are dispensed with. Further, reference numerals are not repeated for all elements already explained and illustrated insofar as the elements themselves and the function thereof have already been described or are known to an expert.

DETAILED DESCRIPTION OF EMBODIMENTS

[0068] The embodiments, which are shown in FIGS. 1 to 4, of moldings 100 and 200 are constructed as decorative elements for the interior of motor vehicles and each have an in-mold-labeling (IML) functional film 110 or 210 which not only is provided for representation of characters or of symbols or structures by a fabric layer 130 or 230, but also can receive control commands for the control of devices (not illustrated) in the vehicle.

[0069] Depending on the construction of the functional film 110 or 210 and the fabric layers 130 or 230, illumination over an entire area and/or illumination only in specific regions for representation of patterns, structures and/or characters or symbols can be achieved.

[0070] The embodiments relate to use of fabric layers 130 or 230 as surface layers, but without in that case having a restrictive effect. Other, already known materials are also usable as a surface layer.

First Embodiment

[0071] FIG. 1 shows a schematic illustration of a molding 100 in a first embodiment.

[0072] The molding 100 has at its visible side 102 a fabric layer 130 which is connected with a functional film 110 by way of an optically conductive layer 140 consisting of a transparent or translucent plastics material.

[0073] The functional film 110 is connected at its rear side with a carrier layer 120 of plastics material. The layer 120 is not transilluminated and can therefore consist of a non-transilluminable plastics material. If the layer 120 is made from a bright (white) plastics material, this can increase the light yield in the direction of the visible side 102 by reflection. By contrast, a dark plastics material for the layer 120 leads to better light shielding in downward direction. The functional film 110 comprises a light source in the form of light-emitting diodes, wherein activation and signal feed as well as power supply take place by way of an electrical connection through the carrier layer 120 or at the side thereof. For that purpose, the carrier layer 120 can have an appropriate opening for reception of connecting lines. In alternative embodiments, the electrical connection is effected at a side region of the carrier layer 120 for contact-making with the corresponding interfaces of the functional film 110.

[0074] The functional film 110 has regions which are embossed or so deformed relative to the remaining region of the functional film 110 that a defined light refraction or deflection in the direction of the visible side 102 takes place when light is introduced laterally. The lateral introduction of light is achieved by way of light-emitting diodes integrated in the functional film 110. The reflective structures produced by the deformed regions form indicia, symbols or patterns. Illumination of these by the light-emitting diodes produces on the visible side 102 a corresponding image through the fabric layer 130. For that purpose the fabric layer 130 is transilluminable.

[0075] The carrier layer 120 has a smaller area dimension than the functional film 110 and the optically conductive layer 140. By comparison with the functional film 110 and the optically conductive layer 140 the fabric layer 130 has an even larger area dimension and is bent over at the sides, the bent-over sections being held at the lower side of the functional film 110 by way of an encircling edge of a plastics material soft component 150. The soft component 150 preferably consists of a black plastics material so that light shielding is achieved. In addition, the soft component 150 acts as a damper so that no chattering or other disturbing noises in the installed state can arise due to, for example, vibrations in operation of the vehicle. Finally, the soft component 150 serves the purpose of retaining the bent-over regions of the fabric layer 130 against the lower side of the functional layer 110. The soft component 150 can be connected at least regionally with the carrier layer 120 by material couple and/or mechanically positive couple. A ‘hard component’, for example acrylonitrile butadiene styrene plastic, can also be used as an alternative to a soft component.

[0076] FIG. 2 shows different states of the molding 100 according to FIG. 1 during manufacture. The molding 100 is produced in an injection-molding process with use of an injection-molding tool.

[0077] In a first step the functional film 110 is provided and inserted into a first cavity of an injection-molding tool. In addition, the functional film 110 can be sucked down therein so as to adopt a defined position or a two-and-a-half-dimensional to three-dimensional deformation, which is retained during manufacture (FIG. 2a).

[0078] In a next step (FIG. 2b) the rear side of the functional film 110, which is opposite the visible side of 102 of the molding 100, is back-molded with a plastics material for formation of the carrier layer 120, which can include mounts or connecting features (clips, detent hooks, screw domes, welding domes, etc.) for later mounting of the molding, these being integrally formed at the carrier layer in the same process step.

[0079] Introduction of the fabric layer 130 into a second cavity of the injection molding tool and injection of transparent or translucent plastics material between the functional film 110 and the fabric layer 130, whereby the optically conductive layer 140 is formed, are subsequently carried out. The optically conductive layer 140 enters into a chemical connection and/or mechanically positive connection with the functional film 110 and the fabric layer 130.

[0080] Bending-over of the fabric layer 130 until the bent-over regions come into contact with the rear side of the functional layer 110 is thereafter carried out as shown in steps c) and d).

[0081] The bending-over of the regions of the fabric layer 130 takes place in a third cavity of the injection-molding tool. Alternatively, this can take place by way of ejectors or pushers in the tool or by means of handling apparatus at the injection-molding machine.

[0082] A third plastics material 150 is subsequently injection-molded on the lower side and forms an encircling edge which holds the bent-over regions against the lower side of the functional film 110. The third plastics material 150 can be connected at least regionally with the carrier layer by material couple and/or mechanically positive couple. Designed as a soft component, for example thermoplastic elastomer, the third plastics material 150 additionally serves for reducing disturbing noises such as chattering or creaking.

[0083] The finished molding 100 can thereafter be removed from the tool and is ready for installation in a vehicle.

Second Embodiment

[0084] FIG. 3 shows a schematic illustration of a molding 200 in a second embodiment.

[0085] The molding 200 differs from the molding 100 in that a diffusing layer 240 of a transparent or translucent plastics material is injection-molded on the rear side of a functional film 210, which is bent over around the diffusing layer 240 like the fabric layer 230.

[0086] An optical conductor 260 is arranged on the lower side of the molding 200 and can be connected with the diffusing layer 240 or arranged at a spacing therefrom. In the illustrated embodiments, even if differently depicted, the light conductor 260 is injection-molded on the lower side of the diffusing layer 240. Light can be introduced into the optical conductor 260 by way of a light-emitting diode or other light source, the light thus illuminating the diffusing layer 240 over the entire area and leading to illumination of the regions 212. The regions 212 of the functional film 210 are optically transmissive and thus produce lighting of the fabric layer 130 in the regions 212.

[0087] The transparent regions 212 later image the desired transilluminating design through the fabric of the fabric layer 230. The cover layer or fabric layer 230 is, like the fabric layer 130, a fabric or technical textile. The molding 200 can be lit by means of a separate optical conductor 260.

[0088] FIG. 4 shows different states of the molding 200 according to FIG. 3 during manufacture.

[0089] In the embodiment, connection of the fabric layer 230 with the functional film 210 takes place in a first step (FIG. 4a). The so-called laminating can be carried out in different ways. It is important that the fabric layer 230 enters into a connection with the functional film 210.

[0090] Back-molding of the functional film 210 with a translucent or transparent plastics material for formation of the diffusing layer 240 takes place subsequently (FIG. 4b).

[0091] In a next step, bending-over of the film 210 and the fabric layer 230 laminated thereon is carried out within the tool, in which case a light barrier for the diffusing layer 240 is achieved.

[0092] An optional further process step (not illustrated) follows the process step of FIG. 2e, wherein after the bending-over of the film 210 and of the fabric layer 230 laminated thereon a soft component is injection-molded on the lower side and forms an encircling edge, which fixes the bent-over regions and similarly has damping and/or light-shielding properties.

[0093] Finally, the optical conductor 260 is thereafter applied from below to the diffusing layer 240 in a concluding step (FIG. 4d).

REFERENCE NUMERAL LIST

[0094] 100 molding [0095] 102 visible side [0096] 110 functional film [0097] 120 carrier layer, first plastics material [0098] 130 surface layer, fabric layer [0099] 140 optically conductive layer, second plastics material [0100] 150 soft component, third plastics material [0101] 200 molding [0102] 202 visible side [0103] 210 functional film [0104] 212 region [0105] 230 surface layer, fabric layer [0106] 240 diffusing layer [0107] 260 optical conductor