Seamless Integration of Illumination into Interior Trim Panels with Decorative Surface Materials

Abstract

A decorative cover for a back-illuminated interior trim panel for a vehicle, said cover being a sturdy shell-structure including a transparent plate, forming the back side of the shell-structure, and a decorative component top layer including a trim material layer, which forms the outer surface of the decorative cover, wherein the trim material layer is formed from a trim material which is one from a group of materials consisting of a wood veneer, a metallic layer, a paper, a textile and a fabric, and wherein the laminate is configured to have a predetermined degree of translucency.

Claims

1. A decorative cover for a back-illuminated interior trim panel for a vehicle, said cover being a sturdy shell-structure comprising a transparent plate, forming the back side of the shell-structure, and a decorative component top layer comprising a trim material layer, which forms the outer surface of the decorative cover, wherein the trim material layer is formed from a trim material which is one from a group of materials consisting of a wood veneer, a metallic layer, a paper, a textile and a fabric, and wherein the decorative component top layer is configured to have a predetermined degree of translucency.

2. The decorative cover according to claim 1, wherein the sturdy shell-structure is formed by back-injecting against the decorative component top layer, such that the sturdy shell-structure is a seamless, single component structure and wherein the decorative component top layer is non-permeable to the back-injected material.

3. The decorative cover according to claim 1, wherein the transparent plate, at predetermined sections, is provided with shading means, for locally reducing an amount of light being transmitted through the plate.

4. The decorative cover according to claim 1, wherein the decorative component top layer is a laminate, which comprises an upper layer consisting of the trim material layer, and a backing material layer.

5. The decorative cover according to claim 4, wherein the backing material layer is formed by one of a fleece, a fabric or a plastic foil.

6. The decorative cover according to claim 1, wherein a back surface of the decorative component top layer is provided with a black-out pattern and/or a fade pattern print, or wherein a further plastic foil layer is provided adjacent the backing material layer, said further plastic foil being provided with the black-out pattern and/or the fade pattern print.

7. The decorative cover according to claim 1, wherein the trim material layer is provided with a coating for protecting the surface from moisture, heat and/or UV exposure.

8. An interior trim panel for a vehicle, comprising the decorative cover according to claim 1, further comprising a light source component comprising: a carrier plate, shaped to form a back surface of the interior trim panel and having a reflective surface, at least one LED light, mounted onto the reflective surface, and a light plate, positioned adjacent to the at least one LED light onto the reflective surface, such that the light plate transfers the light of the at least one LED light over a surface area thereof, wherein the decorative cover is attached to the carrier plate, such that the interior trim panel is a closed light unit with the decorative cover forming a front surface thereof and the decorative cover and carrier plate together enclosing the at least one LED light and light plate.

9. A method of manufacturing a decorative cover for a vehicle interior trim panel comprising a light source component, comprising: providing a non-permeable decorative component top layer, comprising a trim material layer which is formed from a trim material that is one from a group of materials consisting of a wood veneer, a metallic layer, a paper, a textile and a fabric, and which is configured to have a predetermined degree of translucency; optionally, shaping the decorative component top layer into a shell pre-shape having a desired geometry for forming an outer surface of the decorative cover; and back-injecting the decorative component top layer with a translucent material, to form a seamless sturdy shell-structure, with the trim material forming an outer surface and said translucent plastic forming an inner surface of the decorative cover.

10. The method according to claim 9, wherein the providing of a non-permeable decorative component top layer comprises forming a laminate by attaching the layer of trim material onto a backing material layer and optionally further comprising sanding down the layer of trim material to a minimum thickness after attaching said trim material onto the backing material layer to achieve the predetermined degree of translucency.

11. The method according to claim 9, wherein the providing of a non-permeable decorative component top layer comprises the expanding and/or stretching of the layer of trim material and wherein, when the layer of trim material is attached onto a backing material layer afterwards, the backing material layer is a plastic foil.

12. The method according to claim 9, wherein the back-injecting of the component top layer with a translucent material, to form the sturdy shell-structure, is performed with a two component injection process, wherein a first component is the translucent material and wherein a second component is a shading material that reduces light transfer therethrough, wherein said second component is injected in predetermined areas where light from the light source is to be masked.

13. The method according to claim 9, wherein the back-injecting of the component top layer with a translucent material, to form the sturdy shell-structure, is performed with a single component injection process, wherein a translucent material is injected to form the back surface of the decorative cover.

14. The method according to claim 13, wherein prior to the shaping of the component top layer into a shell pre-shape and/or prior to the back-injecting, a black-off pattern and/or a fade pattern print is provided onto the back side of the trim material layer, the backing material layer and/or onto an additional plastic foil layer.

15. A method of manufacturing a vehicle interior trim panel comprising a light source component, comprising: providing the decorative cover according to the method of claim 9; providing a carrier plate, matching the decorative cover, such that said decorative cover can be attached to the carrier plate to form a closed unit which encloses a hollow space, wherein the carrier plate has a reflective surface facing said hollow space; mounting at least one LED light onto the reflective surface, and placing a light plate onto the reflective surface, abutting the at least one LED light, such that the light plate transfers the light of the at least one LED light over a surface area thereof; and attaching the decorative cover to the carrier plate, such that the light plate is in between the carrier plate and the decorative cover.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0040] Embodiments of an interior trim panel according to the present disclosure will be described by way of example, with reference to the attached drawings, in which:

[0041] FIG. 1 shows an embodiment of an interior trim panel with decorative surface material according to the disclosure;

[0042] FIG. 2 shows an exploded view of the interior trim panel of FIG. 1;

[0043] FIG. 3 shows a cross-sectional view of the interior trim panel of FIG. 1 along line III;

[0044] FIG. 4 shows a more detailed cross-sectional view along line III of the decorative panel of FIG. 1; and

[0045] FIGS. 5A and 5B respectively show an example of a fade print and a pattern print for a decorative panel as depicted in FIG. 1.

DESCRIPTION OF EMBODIMENTS

[0046] FIG. 1 shows an embodiment of an interior trim panel 100 with decorative surface material according to the disclosure, with FIGS. 2 and 3 respectively showing an exploded view and a cross-sectional view along line III of the same. The depicted panel 100 may be recognized as a panel for the instrument panel of a vehicle, such as a car, with the decorative surface material forming an external surface of the instrument panel This external surface is facing the inside of the vehicle, such that an occupant thereof may both visually and physically experience the decorative surface material. Similar panels may for example be used on the tunnel console or on the inside of a door panel. The decorative surface material is one of a set of materials consisting of: wood veneer, metallic sheet material, foil, paper, textile or fabric. From hereon, the external surface of the panel formed by the decorative surface material is referenced to as the outer or upper side of the panel 100, and the opposite side of the interior trim panel 100, which faces away from the vehicles interior when installed, is referenced to as the inner or lower side of the panel 100. The skilled person will recognize that vehicle interiors include many more panels, which are not limited to being installed in doorframes, and that the shape of interior trim panels depend on their installation position in the interior as well as the make and model of the vehicle, such that the specific shape of the interior trim panel 100 as depicted may be adapted accordingly.

[0047] The interior trim panel 100 is an assembly consisting of a decorative cover panel 10, and a light source component which consists of a carrier panel 20, a light plate 30 and an LED light 40. The carrier panel 20 is shaped to form the inner side of the interior trim panel 100 and adapted for being attached to the decorative cover panel 10, said panels together forming an enclosed space within which the light plate 30 and the LED light 40 are positioned. Hereto an outline shape of the carrier panel 20 substantially matches with an outline shape of the decorative component 10. The LED light is mounted onto a surface of the carrier panel 20 which faces the decorative cover panel 10. In the depicted light source component, the LED light 40 consists of two LED elements 41, 42, a first of these two LED elements 41 being positioned at a first longitudinal end of the carrier panel 20 and a second of these two LED elements 42 being positioned at a second longitudinal end of the carrier panel 20. The light plate 30 has a size and shape matching with the carrier plate 20, such that the light plate 30, in the assembled position, is press-fitted between the LED elements 41, 42 and sandwiched between the carrier panel 20 and the decorative cover panel 10. Thus, the LED elements 41, 42 flank the light plate 30 on opposite longitudinal ends and the carrier panel 20 and the decorative cover panel 10 flank the light plate 30 on the upper and lower sides. Preferably all parts, with the exception of the light plate 30, are welded together. However, other methods such as tape or clips could also be used.

[0048] Through being flanked by the LED elements 41, 42 at both longitudinal ends, the light plate 30 guides and transfers the light emitted by the LED's to be substantially evenly spread over the surface thereof. The surface of the carrier panel 20 onto which the LED light 40 is mounted is reflective, such that emitted light is reflected off said surface, towards the decorative cover panel 10. The decorative cover panel 10 is adapted to allow a predetermined amount of light shining through, when the LED light 40 is on, whilst having a seamless and solid surface-look with no visible light features when the light is off.

[0049] Hereto, as shown in FIG. 3, the decorative cover panel 10 includes a decorative component top layer 1, a translucent layer 5 and a light shading component 6. The decorative cover panel 10 is formed as a single sturdy shell, with the decorative component top layer 1 including the decorative surface material, which decorative surface material gives the cover panel 10 the seamless and solid-surface look. Although the decorative surface material is one of a set of materials which are generally considered opaque materials, these materials can be adapted to allow a predetermined amount of light shining through, i.e. adapted to have a predetermined translucency for a light positioned directly there behind, such as commonly seen in lampshades for example. Adaptations to achieve a predetermined translucency depend on the specific material chosen, and may include reducing the thickness of the material, expanding or finely perforating the material all-over and/or choosing a material with a particular tightness of warp/weft. To ensure the decorative cover panel 10 is sufficiently sturdy, a relatively thick translucent layer 5 is provided on the inside of the decorative component top layer 1. Further particularities about these layers and how they are combined are discussed down below, in relation to FIG. 4. In order to ensure a smooth light-pattern emitting from the interior trim panel 100, the decorative cover panel 10 is provided with the light shading component 6 at the position of the LED light 40. The light shading component 6 masks the LED light, to prevent a so-called hot-spots occurring directly at the location of each LED. The light shading component 6 may be substantially completely non-transparent, thereby masking off the LED light 40, or include a predetermined transparency, which predetermined transparency is less than the transparency of the translucent layer 5 and results in the LED light being shaded rather than masked off. Both options will be discussed further down below, in relation to FIGS. 4 and 5.

[0050] FIG. 4 shows a more detailed cross-sectional view of the decorative cover panel 10 along line III of FIG. 1. The decorative cover panel 10, top to bottom, includes the trim material layer 1a, a backing material layer 2, an optional plastic foil layer 3, the translucent layer 5 and the light shading component 6.

[0051] The decorative component top layer 1 depicted in FIG. 3 is formed by the trim material layer 1a, the backing material layer 2 and the optional plastic foil layer 3 and is non-permeable to the material of the translucent layer 5, which is back-injected onto the decorative component layer 1. This allows the decorative cover panel 10 being formed in relatively few production steps, using a single injection-molding mold and ensures the seamless and solid surface-look of said panel. The manufacturing steps prior to back-injecting, as well as the presence of plastic foil layer 3 and material choice for the backing material layer 2, depend on the specific material chosen for the trim material layer 1a. Even the presence of the backing material layer 2 may be optional, if the trim material layer 1a is both sufficiently strong, i.e. non-fragile, for being handled on its own during production and non-permeable to the back-injected material for the translucent layer 5. Typically, the decorative component top layer 1 has a thickness ranging between 0.4 mm and 3.8 mm, preferably between 0.6 mm and 1.2 mm, with the translucent layer 5 being between 2 and 3 mm thick and the light shading component being around 1 mm thick. Depending on the trim material used, the decorative component top layer 1 may have a trim material layer 1a of between 0.1 mm and 1 mm, preferably of around 0.3 mm, a backing material layer of between 0.1 and 0.4 mm and a plastic foil layer of between 0.2 and 0.5 mm thickness. For wood veneer, the thickness depends on the veneer type, and is usually in the range of 0.2-0.8 mm.

[0052] For example, when a wood veneer is chosen as the trim material layer 1a. The wood veneer is laminated with a stabilizing translucent backing material 2, such as non-woven fleece or any type of fabric, prior to being sanded down to a minimal thickness required to increase translucency of the wood. The backing stabilizes the wood veneer prior to further processing, allowing it to be handled after the sanding down to minimal thickness, which would otherwise leave the veneer too fragile for further manufacturing steps such as the back injection. The laminate is then pre-shaped into a desired geometry for the interior trim panel 100, after which the laminate is back-injected with translucent material for forming the translucent layer 5, to create the sturdy yet translucent to back-lightening decorative cover panel 10. The wood veneer can be treated with a coating system to protect the surface from moisture, heat and UV exposure after back-injecting.

[0053] An alternative to wood veneer is to use expanded metal as the trim material layer 1a. Expanded metal is sufficiently stable for handling, but through being expanded it lacks the required non-permeability for the material that is to be back-injected. Therefore, the expanded metal is first laminated onto a plastic foil, which plastic foil forms the backing material layer 2 for the expanded metal. Coating treatment of the expanded metal can be performed either before expansion, before lamination onto the plastic foil or after the lamination onto the plastic foil.

[0054] Preferably, the translucent layer 5 is injection molded together with the material forming the structure of the light shading component 6 in a single injection process. This may be through a single material injection molding process, wherein the translucent layer 5 and the structure of the light shading component 6 are both formed by the same translucent material. The material providing the properties for providing the desired shading or masking off of the light shading component 6 may provided in a post-processing step through the application of tape or paint. Preferably, however, the back-injecting is performed with a two component injection process, using a single mold. A first of the two components used in this two component injection process is the translucent material for forming the translucent layer 5 and the second component is a light blocking or shading material for forming the light shading component 6.

[0055] In order to achieve a homogeneous lightening, when fully masking off the LED's, or to achieve a predefined light pattern design shining through the trim material layer 1a, optionally a pattern print may be added to the lower side of the laminate. This pattern print is a so-called black-off pattern and/or a fade pattern, which, when both are applied, may be applied as two independent pattern layers or as a single, merged pattern. The pattern print can be printed directly onto one of the back surface of the trim material layer 1a, the backing material layer 2, or onto an additional plastic foil layer 3, depending on the used trim material, backing material and particular requirements from the light pattern design. The advantage of printing the pattern onto a plastic foil is that a higher resolution print can be achieved than when printing onto fabric or fleece. Where the print is provided onto an additional optional plastic foil layer 3, this layer may be pre-shaped independently from the laminate, provided with an adhesion promotor on a top side thereof and be stacked with the laminate into the mold for being back-injected to form the decorative cover panel 10. An example for a black-off pattern print, for masking off the edges of the light plate 30 and the LED's of the interior trim panel 100, is depicted in FIG. 5A. An example for a fade pattern print for the same panel is depicted in FIG. 5B.

[0056] It will be obvious to the skilled person that the other trim materials listed for use as trim material layer can be processed similarly to the wood veneer and/or expanded metal during the manufacturing of the decorative cover panel 10.

[0057] The present disclosure has been described above with reference to a number of exemplary embodiments as shown in the drawings. Modifications and alternative implementations of some parts or elements are possible, and are included in the scope of protection as defined in the appended claims.