SKIN FOR A VEHICLE INTERIOR TRIM PART COMPRISING A LIGHT SOURCE
20220363190 · 2022-11-17
Inventors
Cpc classification
B60Q3/54
PERFORMING OPERATIONS; TRANSPORTING
B60K35/00
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
The skin (1) comprises at least a translucent elastomeric layer (5) composed of a pigmented plastic material and comprising at least one first portion (8) which is configured to be placed in front of a light source (9). The light of this light source (9) produces an image on this first portion (8) of the translucent layer due to the presence of a surface relief (17, 18) on the surface of the translucent layer (5). A clearly visible image can be obtained by providing even small differences in thickness of the translucent layer (5) when the pigmented plastic material thereof has an average spectral attenuation coefficient (α.sub.av) of between 1.0 and 25 mm.sup.−1. The difference in layer thickness (d.sub.2-d.sub.1) and the average spectral attenuation coefficient (α.sub.av) should moreover be large enough to meet the formula: α.sub.av(d .sub.2−d.sub.1)>-In a, wherein a is equal to 0.50. Since the surface relief (18an automatically be produced when moulding the translucent layer (5) against a mould surface, the image can easily be obtained in the correct position on the skin (1).
Claims
1. A skin for a vehicle interior trim part, which skin comprises at least a translucent elastomeric layer composed of a pigmented plastic material, the translucent layer having an outer surface and an inner surface opposite the outer surface, and the translucent layer comprising at least one first portion which is configured to be placed in front of a light source and to transmit visible light generated by said light source from said inner surface to said outer surface, wherein said first portion of the translucent layer comprises a surface relief on the outer surface and/or on the inner surface thereof to produce an image on said first portion when said visible light is transmitted through said first portion of the translucent layer, which surface relief forms at least one first area, where the translucent layer has a thickness which is smaller than or equal to a first thickness (d.sub.1) and at least one second area, where the translucent layer has a thickness which is larger than or equal to a second thickness (d.sub.2) which is larger than said first thickness (d.sub.1), with the difference (d.sub.2-−d.sub.1) between said first thickness (d.sub.1) and said second thickness (d.sub.2) larger than 0.08 mm but smaller than 3.0 mm, and said pigmented plastic material has over at least one range of visible light wavelengths an average spectral attenuation coefficient (α.sub.av), which average spectral attenuation coefficient is the average of spectral attenuation coefficients (α(λ) determined for different wavelengths (λ) in regular intervals, in particular in intervals of 5 nm, over said range of visible wavelengths by the following formula (I):
α.sub.av(d.sub.2−d.sub.1)>−In a (II) wherein: a=0.50.
2. The skin according to claim 1, wherein in formula (II) a is equal to 0.45, with a being preferably equal to 0.40, more preferably equal to 0.35 and most preferably equal to 0.30.
3. The skin according to claim 1, wherein the difference (d.sub.2−d.sub.1) between said first thickness (d.sub.1) and said second thickness (d.sub.2) is larger than 0.10 mm.
4. The skin according to claim 1, wherein the difference (d.sub.2−d.sub.1) between said first thickness (d.sub.1) and said second thickness (d.sub.2) is smaller than 2.0 mm, preferably smaller than 1.5 mm and more preferably smaller than 1.0 mm.
5. The skin according to claim 1, wherein said average spectral attenuation coefficient (α.sub.av) is larger than 2.0 mm.sup.−1, preferably larger than 3.0 mm.sup.−1, more preferably larger than 4.0 mm.sup.−1 and most preferably larger than 5.0 mm.sup.−1.
6. The skin according to claim 1, wherein said average spectral attenuation coefficient (α.sub.av) is smaller than 20.0 mm.sup.−1, preferably smaller than 15.0 mm.sup.−1 and more preferably smaller than 10.0 mm.sup.−1.
7. The skin according to claim 1, wherein said first portion of the translucent layer has an average thickness which is smaller than 2.0 mm, preferably smaller than 1.5 mm, more preferably smaller than 1.2 mm and most preferably smaller than 1.0 mm.
8. The skin according to claim 1, wherein said first portion of the translucent layer has an average thickness which is larger than 0.2 mm, preferably larger than 0.3 mm, more preferably larger than 0.4 mm and most preferably larger than 0.5 mm.
9. The skin according to claim 1, wherein said range of visible light wavelengths has a width of at least 50 nm, preferably of at least 75 nm, or preferably of at least 150 nm or preferably of at least 300 nm.
10. The skin according to claim 9, wherein said range of visible light wavelengths is the range from 380 to 780 nm.
11. The skin according to claim 1, wherein said first portion of the translucent layer comprises said surface relief on the outer surface thereof.
12. The skin according to claim 1, wherein the skin comprises at least one light source which is adhered to the inner surface of said first portion of the translucent layer and which is configured to emit visible light having a predetermined range of wavelengths, said range of visible light wavelengths corresponding to this predetermined range of wavelengths.
13. The skin according to claim 12, wherein the skin comprises an inner elastomeric layer adhered to the inner surface of said translucent elastomeric layer, with said light source being embedded between said translucent elastomeric layer and said inner elastomeric layer.
14. The skin according to claim 13, wherein said light source comprises at least one LED, in particular a naked LED, which is embedded between said translucent elastomeric layer and said inner elastomeric layer.
15. The skin according to claim 1, wherein the skin comprises a flat screen display, in particular a LED screen, more particularly an OLED screen, which is adhered to the inner surface of a second portion of the translucent layer, which second portion is configured to transmit visible light generated by said flat screen display from said inner surface to said outer surface.
16. The skin according to claim 15, wherein the inner and the outer surface of said second portion of the translucent layer have a surface texture which is completely smooth or which has a Pt value, measured in accordance with DIN EN ISO 4287:1998, which Pt value, in mm, meets the following formula (III):
17. The skin according to claim 15, wherein the skin comprises an inner elastomeric layer adhered to the inner surface of said translucent elastomeric layer, with said flat screen display being embedded between said translucent elastomeric layer and said inner elastomeric layer.
Description
[0051] Other advantages and particularities of the present invention will become apparent from the following description of some particular embodiments of the skin according to the invention. This description is only given by way of example and is not intended to limit the scope of the invention. The reference numerals used in the description relate to the annexed drawings wherein:
[0052]
[0053]
[0054]
[0055]
[0056]
[0057]
[0058] The invention generally relates to a skin 1 for a vehicle interior trim part 2 such as a dashboard, a door panel, a console, a lid of a glove compartment, etc. As can be seen in
[0059] The skin 1 according to the present invention comprises at least a translucent elastomeric layer 5 which is preferably flexible, with an inner surface 6 and an outer surface 7 which forms the visible surface, i.e. the A-surface, of the skin 1. The translucent layer 5 is made of a plastic material which is preferably substantially homogeneously pigmented. The term plastic embraces all synthetic materials including thermosetting and thermoplastic materials. The translucent layer 5 may be a thermoplastic layer or foil, in particular a TPE (thermoplastic elastomer) layer such as a TPO or PVC skin. Such thermoplastic skin layers can be moulded by a thermoforming process or for example by a slush moulding process. The elastomeric translucent skin layer 5 can also be made starting from a curable composition, in particular a curable polyurethane composition. This curable composition is a flowable material which is applied onto a mould surface and which is allowed to cure on that mould surface to produce the translucent skin layer 5.
[0060] The curable composition can either be applied by a spray process against the surface of an open mould or it can be applied in a closed mould, more particularly poured but preferably injected in accordance with a reaction injection moulding (RIM) process. Use can be made of a light-stable coloured PU reaction mixture. Reference can be made to EP-B-0 303 305, EP-B-0 379 246, WO 98/14492, EP-B-0 929 586 and WO 04/000905, which are included herein by reference.
[0061] The translucent skin layer 5 is elastomeric which means that it has generally an elongation, measured in accordance with DIN/EN/ISO 527-3, of at least 30%, preferably of at least 50%. Its flexural modulus, measured in accordance with ASTM D790-03, is preferably smaller than 100 MPa, more preferably smaller than 75 MPa and most preferably lower than 55 MPa or even lower than 40 MPa. Generally, its overall density is larger than 300 kg/m.sup.3, preferably larger than 500 kg/m.sup.3 and more preferably larger than 600 kg/m.sup.3.
[0062] In contrast to the translucent skin layer 5, the substrate layer 3 is relatively rigid and has in particular a flexural modulus, measured according to ASTM D790, higher than 500 MPa, preferably higher than 700 MPa. Although the substrate layer can be made of a thermosetting material, the substrate is preferably made of a thermoplastic material. This thermoplastic material is preferably selected from the group consisting of PC (polycarbonate), ABS (acrylonitrile butadiene styrene) and ABS blends, in particular PC/ABS, SMA (styrene maleic anhydride), PPO (polyphenylene oxide), TPO (thermoplastic olefin), in particular PP (polypropylene), polyacetals, in particular POMs (polyoxymethylenes), nylon, polyester, acrylic and polysulfone. The translucent layer 5 of the skin 1 according to the present invention comprises at least one first portion 8 which is configured to be placed in front of a light source 9 and to transmit visible light generated by the light source from its inner surface 6 to its outer surface 7. The light source 9 is preferably adhered to the inner surface 6 of the translucent layer 5. This is illustrated in
[0063] To adhere the light source 9 to the translucent layer 5, or the light source 9 combined with the operating element 10 when these form one part, the light source 9 can be adhered to the translucent layer 5 by means of an adhesive or it can be applied thereto during the production of the translucent layer 5, when the material of the translucent layer 5 has not yet completely cured. It is also possible to apply the light source 9 onto the substrate layer 3 and to overmould the light source 9 together with the substrate layer 3 with the liquid material used to produce the translucent layer 5.
[0064] In the embodiment illustrated in
[0065] The trim part 2 illustrated in
[0066] To avoid deformations in the area of integration when the product is exposed to different environment temperatures, the integrated printed foil has preferably a shrinkage factor similar to the elastomeric skin and/or the E-modulus (Young's modulus) should be the same or smaller than the E-modulus of the elastomeric layer. A printed foil of TPU material is very appropriate to be used in combination with elastomeric materials.
[0067] The electronic printed foil can already be foreseen of electronic surface mounted devices, like LEDs, haptic actuators, an electric coil for contactless charging, an RFID reader, an antenna, etc. The printed foil can be as well an OLED display.
[0068] A first operating element 10 may be intended to energise the different light sources 9 so that the location of the operating elements 10 becomes clearly visible. It comprises an on/off switch formed by a translucent pressure sensor 13 which has an operating surface 14. The light source 9 behind the translucent pressure sensor 13 comprises two opposite LEDs 15A and 15B. The space between the LEDs is filled with a light guiding material 16 which diffuses the light of the LEDs in different directions to create a uniform lighting of the first portion 8 of the translucent skin layer 5. The operating element 10 can additionally be covered completely or partially by a light filter which filters out certain wavelengths, e.g. to show a coloured image. Such light filters also form part of the light source 9 as they determine the wavelengths of the light which is supplied by the light source 9 to the inner surface 6 of the translucent layer 5. The LEDs 15A and 15B are energized upon initial actuation of the pressure sensor 13 to have a visual indication of the actuation of the operating element 10 and to have a clearer view on the location of the first operating element 10. Also the light sources 9 of other hidden operating elements 10 may be energized upon actuation of the first operating element 10 so that they become visible or more clearly visible to the user.
[0069] To indicate the location of the first operating element 10 when its light source 9 is not energized, the first portion 8 of the translucent skin layer 5 has preferably a first surface texture which is different from a second surface texture, i.e. the surface texture around said first portion.
[0070] Usually, the second surface texture is present over the main part of the surface of the skin. This second surface texture may be for example a leather texture or any other texture that is used for trim parts. Such a leather texture has been illustrated on a larger microscopic scale in
[0071] As illustrated in
[0072] The first surface texture may be produced against a completely smooth mould surface, i.e. against a non-textured mould surface which may even be polished. The second texture is produced against a textured area of the mould surface.
[0073] In order to indicate the location of the first operating element 10 even more clearly without illumination, a surface relief is provided on the outer surface 7 of the first portion 8 of the translucent layer 5. This surface relief is formed by surface relief elements which comprise a central icon 17, indicating the on/off switching function, surrounded by circles of dots 18 which do not only form a clear visual indication but also a clear tactile indication of the location of the first operating element 10. The dots 18 are in fact similar to the raised-points of braille but they are even larger so that they can also be felt easily by unexperienced users. Within the circular icon 17, the surface of the skin is completely smooth so that the recessed area within the circular icon 17 can be clearly felt by the user to indicate where he has to push to actuate the first operating element 10.
[0074] Without the light source 9, or when the light source is not energised, the surface relief on the first portion 8 of the translucent layer 5 can only be seen when there is sufficient ambient light, for example daylight. In accordance with the present invention, the surface relief should also be visible when there is not sufficient ambient light. The surface relief on the first portion 8 of the translucent layer 5 is therefore configured to produce an image on the first portion 8 of the translucent layer 5 by means of the visible light which is generated by the light source 9 and transmitted through the translucent layer 5 from its inner surface 6 to its outer surface 7. The image produced by the surface relief illustrated in
[0075] From the picture shown in
[0076] In accordance with the present invention, it has been found that the desired image can be obtained by particular selections of the thickness difference caused by the surface relief and of the average spectral attenuation coefficient α.sub.av of the pigmented plastic material of the translucent layer 5.
[0077] A test has been done by the inventors to determine the effect of the thickness of the translucent layer on the light transmittance thereof.
[0078] This test has demonstrated an exponential relationship between the layer thickness and the light transmittance through the layer. The light transmittance is the ratio between the illuminance, i.e. the luminous flux (in lux) incident on one surface of the translucent layer and the luminous emittance, i.e. the luminous flux (in lux) emitted from the other surface of the translucent layer. The present inventors have found that the surface relief should preferably reduce the light transmittance of the second thicker area to at least less than 50% of the light transmittance of the first thicker area to create a clearly visible contrast between the different areas and that the larger the difference in light transmission, the better the surface relief elements can be seen.
[0079] In the embodiment illustrated in
[0080] In accordance with the present invention, the difference in thickness between the areas 19 and 20, which should be visually distinguishable on the first portion 8 of the translucent layer 5, i.e. the difference between the first thickness d.sub.1 and the second thickness dz should be at least larger than 0.08 mm but smaller than 3.0 mm. The height h of the icon 17 and the dots 18 should thus be at least larger than 0.08 mm or preferably even at least larger than 0.10 mm.
[0081] The reduction of the light transmittance by the larger thickness dz compared to d.sub.1 is not only dependent on this difference in thickness d.sub.2−d.sub.1 but is also dependent on the average spectral attenuation coefficient α.sub.av. According to the invention this average attenuation coefficient should be larger than 1 mm.sup.−1, or preferably even larger than 2 mm.sup.−1 or more preferably larger than 3 mm.sup.−1 or most preferably larger than 4 mm.sup.−1 or larger than 5 mm.sup.−1. A larger average attenuation coefficient enables indeed to obtain a same reduction of the light transmission with a smaller difference in thickness d.sub.2−d.sub.1 of the translucent layer 5. On the other hand, the average spectral attenuation coefficient α.sub.av should be smaller than 25 mm.sup.−1, or preferably even smaller than 20 mm.sup.−1 or more preferably smaller than 15 mm.sup.−1 or most preferably smaller than 10 mm.sup.−1. In this way, the thickness d.sub.1 of the first thin area 19 can still be large enough, without requiring a too strong light source, to provide the required mechanical properties to the translucent skin layer 5.
[0082] The average spectral attenuation coefficient α.sub.av is to be determined based on the transmittance of a film (sheet) of the pigmented plastic material of the translucent layer 5 which has a uniform thickness which is equal to said first thickness d.sub.1. EN ISO 13468-2:2006 part 2 discloses how to measure the spectral transmittance T.sub.1(λ), i.e. the total transmittance for monochromatic radiation of a given wavelength λ, in intervals of 5 nm, for the whole range of visible wavelengths, i.e. from 380 nm to 780 nm.
[0083] In accordance with the present invention, the spectral attenuation coefficient is then to be determined for each of the wavelengths λwith the formula (I):
[0084] The average spectral attenuation coefficient α.sub.av can then be determined as the mathematical average of these different spectral attenuation coefficients α(λ).
[0085] The average spectral attenuation coefficient α.sub.av can then be calculated for the whole range of visible light wavelengths. This can be done especially when the light source 9 behind the first portion 8 of the translucent layer 5 emits white light, i.e. light which comprises all of the wavelengths between 380 and 780 nm. However, when the light source 9 emits light which comprises a narrower range of wavelengths, the average spectral attenuation coefficient α.sub.av should preferably be determined over this narrower range of wavelengths. If two or more light sources 9, emitting light which comprises different ranges of wavelengths, are provided behind the translucent layer 5, different average spectral attenuation coefficients α.sub.av should preferably be determined, namely as an average over the different ranges of wavelengths, so that the differently coloured images are preferably all produced in accordance with the present invention.
[0086] Apart from the above described selection of the range of thickness differences d.sub.2−d.sub.1 and of the range of average spectral attenuation coefficients determined over the range of wavelengths emitted by the light source (or light sources), a further requirement which has to be met is that α.sub.av and/or d.sub.2−d.sub.1 should be sufficiently large so that α.sub.av(d.sub.2−d.sub.1)>−In a , with the value a being equal to 0.50 (In a being the log.sub.e value or the natural logaritm of a).
[0087] It was found that when the transmittance T.sub.1 of a film (sheet) of the translucent plastic material with the thickness d.sub.1 is defined by the following formula:
T.sub.1=e.sup.−α.sup.
then the transmittance T.sub.2 of a film (sheet) of the translucent plastic material with the larger thickness d2 corresponds at least substantially to the value obtained by the following formula:
T.sub.2=e.sup.−α.sup.
T.sub.2=T.sub.1. e.sup.α.sup.
[0088] When a is equal to 0.50, the transmittance of the second thicker area 20 is thus at least about 50% smaller than the transmittance of the first thinner area 19. This makes the second area 20 clearly visually distinguishable from the first area 19 when the light source 9 is energised. Preferably, a larger contrast between the first 19 and the second area 20 is obtained by reducing the value a to equal to 0.45, preferably equal to 0.40, more preferably equal to 0.35 and most preferably equal to 0.30. For these a values, the reduction of the transmittance of the thicker area 20 corresponds substantially to a reduction of respectively 55%, 60%, 65% and 70%.
[0089] As described already here above, in the embodiment illustrated in
[0090] Based on the formula T.sub.1=e.sup.−α.sup.
[0091] In the embodiment illustrated in
[0092] When the translucent layer 5 would be produced against the surface of the rigid part containing the light source 9 and any operating element 10, the surface relief could also be formed on the inner surface 6 of the translucent layer 5. In this way, as a result of the difference in transmittance produced again by the surface relief, an image would also be obtained on the outer surface 7 of the translucent layer 5 when the light source 9 is energised. A negative of the surface relief could be provided on the surface of the light source which is directed towards the translucent layer and the translucent layer could be produced for example by a reaction overmoulding process partially against that surface of the light source. It is also possible to provide a surface relief both on the inner 6 and onto the outer surface 7 of the translucent layer 5.
[0093] Due to the fact that the translucent layer 5 is made of a pigmented material having said average spectral attenuation coefficient, it is also possible to provide a flat screen display on the back of the translucent layer 5. Such a flat screen display 21 has been illustrated schematically in
[0094] The outer surface 7 of the second portion 22 of the translucent layer 5 is preferably completely smooth or it may show some surface texture or roughness so that it is less glossy and matches better with the surrounding surface area so that it is less visible when the display 21 is not energised. Preferably, the inner 6 and the outer surface 7 of said second portion 22 of the translucent layer 5 have a surface texture which is completely smooth or which has a Pt value, measured in accordance with DIN EN ISO 4287:1998, which Pt value, in mm, meets the following formula (III):
wherein b is larger than 0.50, preferably larger than 0.60 and more preferably larger than 0.70 and wherein the average spectral attenuation coefficient (α.sub.av) is preferably determined for any range of visible light wavelengths emitted by the flat screen display.
[0095] The difference in light transmittance between the peaks of said texture and the valleys thereof is therefore smaller than about 50%, or preferably smaller than 40% or smaller than 30%. Locally, a relief element can be provided in the second portion 22 of the translucent layer 5 to provide an additional image thereon in front of the image created by the flat screen display 21.
[0096] As can be seen in