COMPONENT COMPRISING A COVER LAYER AND METHOD FOR PRODUCING A COMPONENT OF THIS KIND

Abstract

The invention discloses a method for producing a component having a base element (1), which has a front side (10) delimited by an outer edge (11), a rear side (14) and one or more side surfaces (15) that connect the front side (10) to the rear side (14). The component also has a cover layer (2) formed of a coating, said layer being sprayed onto the base element (1), wherein during spraying, the coating is guided through one or more supply channels (16), which extend continuously through the base element (1) to the front side (10) and/or to one or more side surfaces (15). During spraying, the coating is flooded onto at least part of the side surfaces (15).

Claims

1. A method for producing a component with a base element, which has a front side front side delimited by an outer rim, a rear side and one or more side surfaces which interconnect the front side and the rear side, and with a cover layer, formed from a lacquer, which is injection molded on the base element, wherein the lacquer, during the injection molding, is directed through one or more feed channels which extend continuously through the base element toward the front side and/or toward one or more of the side surfaces, and wherein the lacquer, during the injection molding, is flooded onto at least a part of the side surfaces.

2. The method as claimed in claim 1, wherein the lacquer, during the injection molding, is flooded over and beyond the outer rim of the front side.

3. The method as claimed in claim 1, wherein the lacquer has a viscosity in the range of between 40 mPa*s and 500 mPa*s, measured at 65 C.

4. The method as claimed in claim 1, wherein the base element has at least one rear edge at which the rear side and the side surface, or side surfaces, meet each other, and wherein the lacquer, during the injection molding, floods over a part of the side surfaces up to this rear edge so that the cover layer completely covers the corresponding part of the side surfaces from the front side up to the rear edge.

5. The method as claimed in claim 1, wherein the cover layer is at least partially translucent.

6. The method as claimed in claim 5, wherein at least one lighting element is provided in order to illuminate the component through the feed channel(s).

7. The method as claimed in claim 5, wherein the cover layer forms a diffuser.

8. The method as claimed in claim 5, wherein a plurality of feed channels is provided which each have an opening, wherein the largest possible inner circle of a respective opening has a diameter of between 0.2 and 5 mm, and wherein the center points of the inner circles have a mutual distance of at least 0.4 mm.

9. The method as claimed in claim 5, wherein during the injection molding a projection, which in each case protrudes relative to the rear side of the base element, is formed in the region(s) of the feed channel(s), and wherein this/these projection(s) serves/serve as a light conductor in the component in order to conduct light to the front side and/or side surface.

10. The method as claimed in claim 1, wherein the component also has an add-on part which covers at least a part of the front side and/or side surface, and which during the injection molding is in contact with the lacquer and consequently is connected to the cover layer.

11. The method as claimed in claim 10, wherein the add-on part is arranged between the base element and the cover layer.

12. The method as claimed in claim 11, wherein the base element has at least one forward projecting baffle wall in the region of its front side in order to protect the add-on part during the injection molding.

13. The method as claimed in claim 11, wherein the feed channel(s) extends/extend through the add-on part so that the lacquer, during the injection molding, is directed through the add-on part toward the front side and/or side surface.

14. The method as claimed in claim 10, wherein the add-on part is a foil or an electronic unit.

15. The method as claimed in claim 10, wherein the cover layer is arranged between the base element and the add-on part.

16. The method as claimed in claim 15, wherein the add-on part is a foil.

17. The method as claimed in claim 1, wherein the front side of the base element has local elevations and/or recesses.

18. The method as claimed in claim 1, wherein the component is intended for the automobile industry.

19. A component having a base element with a front side, a rear side and with one or more side surfaces which interconnect the front side and the rear side, and a cover layer which covers at least a part of the side surfaces and is made of a lacquer injection molded on the base element, wherein the base element has one or more feed channels which extend continuously through the base element toward the front side and/or toward one or more of the side surfaces, and wherein the lacquer extends through the one or more feed channels.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0041] Preferred embodiments of the invention are described in the following text with reference to the drawings which serve purely for explanation and are not to be interpreted as being limiting. In the schematically represented drawings in each case:

[0042] FIG. 1 shows a suitable injection mold for use in the method according to the invention for producing the base element;

[0043] FIG. 2 shows the production of the base element in the injection mold of FIG. 1;

[0044] FIG. 3 shows the base element after its removal from the injection mold of FIG. 1;

[0045] FIG. 4 shows the production of a component according to the invention in a further injection mold;

[0046] FIG. 5 shows a plan view of the base element of a component according to the invention with the diameters and distances of the openings of the feed channels;

[0047] FIG. 6 shows a finished component according to one embodiment according to the invention;

[0048] FIG. 7 shows a finished component according to another embodiment according to the invention;

[0049] FIG. 8 shows a base element and also an electronic unit of component according to the invention according to another embodiment, before the injection molding of the cover layer;

[0050] FIG. 9 shows the base element and the electronic unit of FIG. 8 installed therein, with foil attached thereto, before the injection molding of the cover layer for producing a component according to a further embodiment;

[0051] FIG. 10 shows the base element, inserted in an injection mold, with electronic unit inserted therein and foil of FIG. 9 attached thereon, directly before the injection molding;

[0052] FIG. 11 shows the component, removed from the injection mold of FIG. 10, after the injection molding, which corresponds to a further embodiment according to the invention;

[0053] FIG. 12 shows the component of FIG. 11 after its installation and after removal of the protective foil; and

[0054] FIG. 13 shows a plan view of the component of FIG. 12.

DESCRIPTION OF PREFERRED EMBODIMENTS

[0055] Shown in FIGS. 1 to 4 are the essential method steps of a method according to the invention for producing a component according to the invention. FIG. 5 illustrates a preferred embodiment of the base element 1 of a component according to the invention. Shown in FIGS. 6 and 7 are different embodiments of finished components according to the invention. FIGS. 8 to 10 illustrate essential method steps of another method according to the invention for producing another component according to the invention, as is shown in FIGS. 11-13. Elements with an identical or similar technical function and effect are provided in each case with the same reference numerals in FIGS. 1 to 13.

[0056] FIG. 1 shows an injection mold 6 which serves for producing a base element 1 of a component according to the invention. The finished base element 1 is shown in FIG. 3. The injection mold 6 has a first injection mold 60 and a second injection mold 61 which in accordance with FIG. 2 can be joined together in such a way that a cavity is formed therebetween in the desired shape of the base element 1.

[0057] The first injection mold 60 forms a front side 10 and the encompassing side surface 15 of the base element 1.

[0058] The second injection mold 61 forms a rear side 14 of the base element 1, which in this case is a planar design. The injection mold 61 also has a plurality of projections 63 which serve for forming teed channels 16 in the finished base element 1. The projections 63 are of cylindrical shape in each case and extend upward parallel to each other. In the closed state of the injection mold 6, the projections 63 butt against the first injection mold 60 by their end faces in each case, as is apparent from FIG. 2.

[0059] The second injection mold 61 also has injection channels 62 for injecting plastic into the cavity which is formed by the injection molds 60 and 61 in the closed state of the injection mold. The injection channels 62 are formed by a main channel and a plurality of end channels. The main channel branches in this case into the end channels which directly open into the cavity.

[0060] For producing the base element 1, as is shown in FIG. 2, plastic in a fluid or at least flowable form is injected through the injection channels 62 into the cavity which is formed by the injection mold 60 so that the cavity is completely filled up with plastic.

[0061] After the plastic has hardened, the base element 1, as shown in FIG. 3, can be demolded, i.e. removed from the injection mold 6.

[0062] The base element 1 has a front side 10 of planar design and a rear side 14, also of planar design, which extends parallel thereto. The front side 10 is bordered by an encompassing outer rim 11. At the sides, the front side 10 and the rear side 14 are interconnected by an encompassing side surface 15. The side surface 15 is in this case of curved design in such a way that in the cross-sectional view of FIG. 3 it extends from the rim 11 of the front side 10 via a quarter of an arc to the rear side 14. The base element 1 has a rear edge 19 at which the rear side 14 and the side surface 15 meet each other and include an angle of 90 there.

[0063] Extending through the base element 1 perpendicularly to the front side 10 and to the rear side 14 are a plurality of feed channels 16 which are arranged parallel to each other. The teed channels 16 are of sleeve-like, in particular cylindrical, design and each have a mouth which opens outward inside the front side 10, and a second mouth which opens outward inside the rear side 14.

[0064] For producing the component, the base element 1 is now inserted in another injection mold 7, as is shown in FIG. 4. The injection mold 7 is designed similar to the injection mold 6 but forms a slightly larger cavity and has a different arrangement of injection channels.

[0065] With the injection mold 7 closed, the base element 1 lies with its rear side 14 on a first, lower injection mold 71. A space 73, the design of which describes the shape of the cover layer 2 of the finished component 1, remains in the region between the front side 10 and the encompassing side surface 15 of the base element 1 on one side, and a second, upper injection mold 70 on the other side. The space 73 in this case is sealed toward the outside, at least with regard to the lacquer which is to be injected, in particular in that region where the two injection molds 70 and 71 butt against each other. The space 73 preferably has a height H of between 0.3 and 1.5 mm. The height H corresponds to the thickness D (FIG. 7) of the cover layer 2 which is to be produced.

[0066] Formed in the lower injection mold 71 are injection channels 72 which have a main channel and a plurality of end channels which branch off from this. The end channels open in each case directly into one of the feed channels 16 of the base element 1 which is inserted in the cavity of the injection mold 7. In order to facilitate removal of the component from the mold after the injecting molding, the end channels of the injection channels 72 are advantageously of conical design in each case, as shown in FIG. 4, with an opening angle which widens in the direction of the base element 1.

[0067] For producing the cover layer 2, a lacquer is now injected through the injection channels 72 and via the feed channels 16 into the space 73. In this case, the lacquer first of all completely floods over the front side 10 and then the encompassing side surface 15 of the base element 1 respectively. In this way, the base element 1, toward the side facing the observer, is completely coated with a cover layer 2 which is formed from the lacquer. If the finished component lies with its rear side 14 of planar design on an installation surface which is also of planar design, the base element 1, providing the cover layer 2 is opaque, is not visible at any point and from any direction of view. On account of injecting through the base element 1, the visible surface of the cover layer 2 has no irregularities, moreover. Use is preferably made of a lacquer which preferably at a point in time at which the lacquer begins to harden advantageously has a viscosity in the range of between 40 mPa*S and 500 mPa*s, measured at 65 C. With such viscosity values, good flowability of the lacquer is ensured. The viscosity is advantageously measured according to DIN 53019-1 Standard, September 2008 edition. The measuring of the viscosity is preferably carried out using a cone and plate rotational viscometer which features a fixed measuring cup and a rotating measuring body. For measuring the viscosity, for example the Rheomat R 180 viscometer made by the proRheo GmbH Company (Bahnhoffstrasse 40/2, 75382 Althenstett, Germany) can be used.

[0068] In preferred embodiments, use is made of a lacquer which after hardening forms a transparent or translucent cover layer 2. As a result, the base element 1 can be visible for the observer through the cover layer 2. The cover layer 2 preferably has a thickness D of between 0.3 and 1.5 mm.

[0069] As is apparent in FIG. 5, the base element 1 according to FIG. 5 has three feed channels 16. In the plan view of the base element 1, a first feed channel 16 has a triangular opening, a second feed channel 16 has a square opening, and a third feed channel 16 has an opening designed as a circle. So that the feed channels 16 formed in the base element 1 enable injection of the lacquer onto the base element 1 in such a way that the lacquer has not already hardened before it has reached all points of the base element 1, and also so that the component can be adequately, in particular homogenously, illuminated through the feed channels 16, the feed channels 16 should preferably have in each case an opening with a largest possible inner circle 191 which has a diameter d.sub.1, d.sub.2 and d.sub.3 of between 0.2 and 5 mm, preferably between 1 and 5 mm, and the middle points M of the inner circles 191, moreover, should preferably be arranged with a mutual distance m.sub.1, m.sub.2 and m.sub.3 of at least 0.4 mm from each other (see FIG. 5). In the case of more than three feed channels 16, the additional feed channels would be arranged and dimensioned accordingly.

[0070] In the case of the embodiment of a finished component shown in FIG. 6, a light conductor 80, which is accommodated in a housing 81, butts against the rear side 14 of the base element 1. The light conductor 80 butts in this case against the transparently or translucently formed lacquer particularly in the regions of the feed channels 16 in each case. The housing 81 is attached in an encompassing manner by means of an adhesive 82 in the region of the rear edge 19 of the base element 1. In addition to the light conductor 80, provision is also made inside the housing 81 for a lighting element 3, for example in the form of an LED, which is arranged at the side toward of the light conductor 80.

[0071] The light which is radiated from the lighting element 3 is coupled into the light conductor 80 and is directed through this toward the feed channels 16 and into these. Via the lacquer which is arranged in the feed channels 16, the light makes its way toward the front side 10 and also the side surface 15 of the base element 1 and therefore into the cover layer 2. On account of the transparency or translucency of the cover layer 2, the light is finally radiated in the direction of the observer and brings about a specific visual effect in this case. If the cover layer 2 has the properties of a diffuser, the light can be distributed evenly over the entire cover layer 2 and can be correspondingly radiated toward the observer.

[0072] After removal of the component from the injection mold 7, there are projections 20 protruding in each case on the rear side 14 of the base element 1 which are created on account of the injection channels 72 and can be removed. In the case of the embodiment of a component shown in FIG. 7, these projections 20 have not been removed, however, but serve as light conductors in order to transport the light radiated from the lighting elements 3 into the feed channels 16.

[0073] In the case of the embodiment shown in FIG. 8, the front side 10 of the base element 1 has a multiplicity of local elevations 12 and local recesses 13. Some of the feed channels 16 open inside a recess 13 and some open outward inside an elevation 12. The base element 1 is in this case altogether of essentially cuboid design and has four side surfaces 15 which are perpendicular to each other in each case. The front side 10 and the rear side 14 extend in each case perpendicularly to the side surfaces 15. The outer rim 11 of the front side 10 is formed in this case by an encompassing front edge at which the front side 10 and the corresponding side surface 15 each include an angle of 90 (see FIG. 8).

[0074] One of the recesses 13 serves for accommodating an electronic unit 5. The electronic unit 5 forms an add-on part and has a printed circuit board 50 with a plurality of electronic components, which are not shown in the drawings. A power cable 51 serves for supplying the electronic unit 5 with electric power.

[0075] On the rear side 14 of the base element 1, a projecting fastening element 18 is provided which serves for the fastening of the finished component in the region of an installation surface.

[0076] During production of the component, the electronic unit 5, as is shown in FIG. 9, is inserted into the recess 13 which is correspondingly provided for it. Retaining elements 53, attached on the rear side of the printed circuit board 50, are in this case inserted into local recesses of the base element 1 which are formed correspondingly complementary to the retaining elements in order to fasten the electronic unit 5 on the base element 1. The power cable 51 in this case is guided through the base element 1 via one of the feed channels 16. A sealing plug 52, which is attached to the electronic unit 5, prevents the lacquer from being able to find its way into the feed channel 16.

[0077] The printed circuit board 50 has a through-opening 54 which comes to lie directly adjacent to one of the feed channels 16 so that this opens directly into the through-opening 54.

[0078] As the next step, a foil 4 is attached on the base element 1 in such a way that it completely covers the entire front side 10, the electronic unit 5 and all the side surfaces 15. The adhesion of the foil 4, which constitutes a further add-on part of the component, on the base element 1 can be achieved for example by means of electrostatic charging of the foil 4. The foil 4 in the present case can be a protective foil. The foil 4 can, however, instead of or in addition to the retaining elements 53 also be used in order to fasten the electronic unit 5 or another add-on part on the base element 1 before the injection molding.

[0079] The injection molding of the lacquer onto the front side 10 of the base element 1 is shown in FIG. 10 and is carried out essentially in a similar way to the procedure already explained with reference to FIG. 4. In contrast to the method of FIG. 4, the lacquer in this case is not only directed through the feed channels 16 toward the front side 10, however, but additionally also through the printed circuit board 50 of the electronic unit 5. The lacquer, after passing through the through-opening 54, consequently flows directly over the electronic unit 5, as a result of which any lateral forces acting upon the electronic unit 5 are substantially reduced. The injecting of the lacquer through the through-opening 54 can prevent displacement of the electronic unit 5 in particular even in cases in which the electronic unit 5 does not butt against, or only partially butts against, a local elevation 12.

[0080] In order to protect the electronic unit 5 from the pressure of the inflowing lacquer and/or in order to avoid a flow under the electronic unit 5, provision is made adjacent to this for a baffle wall 17 which is formed by one of the elevations 12. On account of the baffle wall 17, the lacquer makes it way to the electronic unit 5 from above in any case during the injection molding.

[0081] During the injection molding in the injection mold 7 shown in FIG. 10, the foil 4 becomes detached from the base element 1 and from the electronic unit 5 on account of the injection pressure and is pressed against the inner wall of the upper, first injection mold 70. In this case, the foil 4 is connected to the lacquer so that it adheres to the finished cover layer 2. This is shown in FIG. 11.

[0082] Shown in FIG. 12 is how the finished component according to FIG. 11 is installed by means of the fastening element 18. After installation, the foil 4 is pulled off from the cover layer 2 and disposed of. The projections 20 protrude in this case into a recess, provided inside an installation surface, in which lighting elements 3 are also arranged. Via the projections 20 and through the hardened lacquer which is arranged in the feed channels 16, the light radiated by the lighting elements 3 makes its way into the cover layer 2 and from this to the observer. The lighting elements 2 are attached on a common printed circuit board 30 which is supplied with electric power by means of a power cable 31.

[0083] The elevations 12 and recesses 13 which are formed on the front side 10 of the base element 1 can form a logo and/or a symbol which can be seen in the finished component by the observer.

[0084] The invention is naturally not limited to the previously described embodiments, and a large number of variations are possible. In this respect, the feed channels for example do not necessarily have to open outward inside the rear side of the base element but can also do this for example inside the side surfaces. Moreover, the feed channels can have a different shape as shown for example in the Figures. The openings according to FIG. 5 have a triangular shape, a square shape and are also formed in the shape of circle. Naturally, these openings can have a shape which is different to those shown in FIG. 5. Any shapes for the openings are possible. In the case of the add-on part, it does not necessarily have to be an electronic unit for a foil but can be any other part. The add-on part can for example also be formed by a layer or a coating. The production of the base element does not necessarily have to be carried out in an injection molding process but can take place in any other way. The base element can also have an optional shape. A large number of further variations are possible.

TABLE-US-00001 LIST OF REFERENCE NUMERALS 1 Base element 10 Front side 11 Rim 12 Elevation 13 Recess 14 Rear side 15 Side surface 16 Feed channel 17 Baffle wall 18 Fastening element 19 Rear edge 191 Inner circle 2 Cover layer 20 Projection 3 Lighting element 30 Printed circuit board 31 Power cable 4 Foil 5 Electronic unit 50 Printed circuit board 51 Power cable 52 Sealing plug 53 Retaining element 54 Through-opening 6 Injection mold 60 First injection mold 61 Second injection mold 62 Injection channels 63 Projections 7 Injection mold 70 Upper injection mold 71 Lower injection mold 72 Injection channels 73 Space 80 Light conductor 81 Housing 82 Adhesive d.sub.1, d.sub.2, d.sub.3 Diameter m.sub.1, m.sub.2, m.sub.3 Distance Angle D Thickness H Height M Center point