METHOD FOR PRODUCING A DECORATIVE ELEMENT HAVING A FUNCTIONAL OPENING AND DECORATIVE ELEMENT

Abstract

A method for producing a decorative element and a decorative element with a functional opening, which is intended for a motor vehicle. In the method, a decorative blank which has a through opening and a functional coating is provided. A composite including the decorative blank and the functional coating is also produced by fixing the decorative blank to the functional layer via its fastening side. The through opening of the decorative blank is filled with a filling material, and the through opening is further developed into the functional opening.

Claims

1. A method for producing a decorative element for a motor vehicle having a functional opening, the method comprising: providing a decorative cut-out, the decorative cut-out including a through hole; providing a functional layer; producing a composite including the decorative cut-out and the functional layer by fixing the decorative cut-out to the functional layer using an attachment side of the decorative cut-out; and filling the through hole of the decorative cut-out with a filling material to form the functional opening.

2. The method according to claim 1, further comprising: forming a decorative blank from a first blank material portion and a second blank material portion, wherein the through hole is formed by a gap between the first blank material portion and the second blank material portion.

3. The method according to claim 2, further comprising cutting the through hole into the first blank material portion such that the through hole corresponds to the second blank material portion, and inserting the second blank material portion into the through hole so that the through hole is partially filled by the second blank material portion.

4. The method according to claim 1, wherein the filling material is translucent in a final state.

5. The method according to claim 4, wherein the filling material is image-true transparent in the final state.

6. The method according to claim 1, further comprising gluing together the decorative cut-out and the functional layer by filling the through hole with the filling material.

7. The method according to claim 1, wherein the functional layer is includes a first functional layer and at least one second functional layer, and the producing the composite further comprises fixing the first functional layer and the at least one second function layer to the decorative cut-out.

8. The method according to claim 1, further comprising fastening at least one of an electrical arrangement and an electronic arrangement of the decorative element in a carrier region of the functional layer corresponding to the through hole of the decorative cut-out.

9. The method according to claim 1, further comprising at least partially removing the functional layer from the decorative cut-out after the through hole has been filled.

10. The method according to claim 1, further comprising cutting a second through hole into the functional layer, and the second through hole corresponds to the through hole of the decorative cut-out.

11. The method according to claim 1, wherein the functional layer is at least partially fluid-permeable.

12. The method according to claim 1, wherein the functional layer is at least partially translucent.

13. The method according to claim 12, wherein the functional layer is image-true transparent.

14. The method according to claim 1, further comprising forming a fastening element for at least one of an electrical apparatus and an electronic apparatus of the decorative element on the attachment side of the decorative cut-out.

15. The method according to claim 1, further comprising providing a spacing device between a fastening side of the functional layer and a fastening side of the decorative cut-out to space the decorative cut-out and the functional layer apart from one another by a distance.

16. The method according to claim 1, further comprising providing a holding element arranged on an attachment side of the functional layer, the holding element dips into the through hole of the decorative cut-out, and holding at least one of an electrical arrangement and an electronic arrangement of the decorative element in the through hole by the holding element.

17. A decorative element for a motor vehicle, the decorative element is produced by the method according to claim 1.

Description

DRAWINGS

[0048] In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which:

[0049] FIG. 1 is a schematic view of a decorative cut and a functional coating, wherein the respective decorative cut-out has a through hole according to the present disclosure;

[0050] FIG. 2 is a schematic view of a decorative element or a composite of the decorative cut-out and the functional coating, which is formed from the decorative cut-out and the functional coating according to the present disclosure;

[0051] FIG. 3 is a schematic and sectional view of a composite of the decorative cut-out and the functional coating, showing different through holes according to the present disclosure;

[0052] FIG. 4 is a schematic and sectional view of the decorative element, wherein an electrical and/or electronic apparatus of the decorative element is attached in a carrier region of the functional coating according to the present disclosure;

[0053] FIG. 5 is a schematic and sectional view of the decorative element having a fastening element for the electrical and/or electronic apparatus according to the present disclosure;

[0054] FIG. 6 is a schematic and sectional view of the decorative element with a lighting device according to the present disclosure;

[0055] FIG. 7 is a schematic and sectional view of the decorative element with the light device in another possible example according to the present disclosure; and

[0056] FIG. 8 is a schematic and sectional view of the decorative element, wherein a spacer device is formed between the decorative cut and the functional layer according to the present disclosure.

[0057] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

DETAILED DESCRIPTION

[0058] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features and Identical and functionally identical elements are provided with the same reference numerals in the figures.

[0059] In the following, a method for producing a decorative element 1 (shown for the first time in FIG. 2) and the decorative element 1 itself are presented in a joint description. FIG. 1 shows a schematic view of a decorative cut-out 2 and a functional coating 3. The decorative cut-out 2 and the functional coating 3 are provided or produced in a first step of the method. In the present case, the decorative cut-out 2 has several cut material parts 4, 5, 6, 7. In the process, the decorative cut-out 2 is therefore composed of the cut material parts 4, 5, 6, 7. The decorative cut-out 2 has a through hole 8, 9, 10, whereby the through holes 8, 9 are part of the first cut material portion 4 and the through hole 9 is part of the cut material portion 5. In contrast, the cut material portions 6, 7 are free of a through hole. The respective geometric shape of the through holes 8, 9, 10 and of the decorative cut-out 2 and the functional layer 3 is to be understood as merely exemplary. The decorative cut-out 2 has a visible side 11 and an attachment side 12, which are spaced out by a thickness of the decorative cut-out 2 or the cut material portions 4, 5, 6, 7 and are opposite one another.

[0060] The functional coating 3 has an attachment side 13 and a rear side 14, which are spaced apart by a thickness of the functional coating 3 and are opposite one another. In the present example, the functional attachment 3 is provided with a through hole 15, for example by cutting the through hole 15 into the functional coating 3. The through hole 15 can completely penetrate the functional layer 3. The through hole 15 is formed in/on the functional coating 3 in such a way that it corresponds to one of the through holes 8, 9, 10in this case with the through hole 10of the decorative cut-out 2. It can also be seen that a web arrangement 24 having at least one web 23 can pass through the through hole 15 of the functional coating 3, so that an inner portion 25 and an outer portion 26 of the functional coating 3 are connected to one another by means of the web arrangement 24. The functional coating 3 is further designed to be fluid-permeable in some areas or over its entire surface. In addition, the functional coating 3 is translucent in some areas or over its entire surface, transparent and true-to-image.

[0061] By carrying out further steps of the method, at least the decorative cut-out 2 is formed. Since the decorative cut-out 2 or is formed from it, the cut material parts 4, 5, 6, 7 are further processed to form the decorative element 1. For this purpose, a composite 16 is produced, which is shown in a schematic view in FIG. 2 and has the cut material parts 4, 5, 6, 7, i.e. the decorative cut-out 2, and the functional layer 3. The composite 16 is produced by fixing cut material parts 4, 5, 6, 7 via their fastening side 12 to the fastening side 13 of the functional coating 3. In this case, a gap 19 is formed between edges 17, 18 of the cut material parts 4, 5, which represents a further through coating 20 of the decorative cut-out 2. The cut material parts 4, 5 are therefore spaced apart from one another on the fastening side 13 of the functional layer 3 via the gap 19, e.g. via the through hole 20.

[0062] As can be seen from a comparison of FIG. 1 with FIG. 2, in the present case the cut material parts 6, 7 are inserted into the associated through holes 8, 10 to produce the composite 16, so that the respective through hole 8, 10 is partially filled by the corresponding cut material part 6, 7. In this case, a respective annular gap 21, 22 is formed between the cut material parts 6, 7 and the cut material parts 4, 5, which is free of a material of the cut material parts 4, 5, 6, 7. The corresponding through hole 8, 10 is thus partially occupied or filled by the associated cut material portion 6, 7.

[0063] In principle, the edges of the functional coating 3, such as edges of the through coating 15 or outer edges, can be used to position the cut material portions 6, 7 as desired. For example, the edges, such as outer edges, of the cut material portions 6, 7 can be aligned precisely with the associated edges of the functional layer, with the edges then lying flush on top of one another. Alternatively, an oversize or undersize can be specified, by which the corresponding edge of at least one of the cut material portions 6, 7 is spaced from the associated edge of the functional coating in at least one edge section. The corresponding cut material portion 6, 7 can then protrude beyond the functional layer 3 at the edge or vice versa. In the event that an edge of the cut material portion 6, 7 or an edge of the functional layer 3 has an uneven, for example wave-like, course, the wave troughs or wave crests can be used as the decisive element for the alignment. Alignment via a laser projection is also a possibility.

[0064] The method also uses a filling material 27 with which at least one of the through holes 8, 9, 10, 20 of the decorative blank or decorative cut-out 2 is completely or partially filled or filled. By filling the respective through hole 8, 9, 10, 20, the corresponding through holes 8, 9, 10, 20 is further developed into a functional opening 28. In the present example, the filling material for filling the through holes 8, 9, 10, 20 is brought into an at least pasty, in this case at least approximately liquid, state or is already provided in this state. This means that when the through holes 8, 9, 10, 20 are filled, a material-locking connection is produced at least between the decorative blank or decorative cut-out 2 and the filling material 27. As a result, the composite 16 is stabilized or reinforced by filling it with the filling material 27. The filling material 27 has the adhesive properties of an adhesive or is an adhesive. Furthermore, the filling material 27 is translucent in its fully reacted state, e.g. permeable to visible light. In order to achieve a diffuse light distribution or light appearance on the visible side 11, in the present example it is provided that the filling material 27 is milky in the fully reacted state. By filling the corresponding one of the through holes 8, 9, 10, 20 with the filling material 27, a light opening 29 (see FIG. 3) is at least partially formed from it. For filling the through openings 8, 9, 10, 20, a coating process (such as a doctor blade and/or screen printing process), a reaction injection molding process (RIM), in particular a clear RIM process with transparent polyurethane, a roller coating process or transfer roller process with hot melt, a casting process and/or a casting process, in particular a low-pressure injection molding process, with a hot melt adhesive are used.

[0065] In the present case, it is also provided that the functional coating 3 and the decorative cut-out 2 are glued together while filling the through holes 8, 9, 10, 20 or one or some of the through holes 8, 9, 10, 20 with the filling material 27. The filling material 27 acts as an adhesive between the decorative cut-out 2 and the functional coating 3. Thus, in an advantageous manner, the (respective) through hole 8, 9, 10, 20 is filled with the filling material 27 and the functional coating 3 and the decorative cut-out 2 are glued together using just one single, common step in the work process. At least one portion of the filling material 27 penetrates from the corresponding through holes 8, 9, 10, 20 between the functional coating 3 and the decorative cut-out 2 and connects the functional coating 3 and the decorative cut-out 2 at their attachment sides 12, 13 in a material-locking manner.

[0066] FIG. 2 also shows an electrical and/or electronic arrangement 30, which can have, for example, a sensor system (image, air pressure, temperature sensor, etc.), a heating or air conditioning device 31 (see FIG. 3), etc. In particular, the arrangement 30 here has a lighting device 32, which in turn has a light source, a light guide, light-directing elements, etc. A last element of the lighting device 32 in the direction of light can be formed, for example, by the translucent or transparent filling material 27, which is backlit during operation so that the light from the light source shines out of the filling material 27. Furthermore, the lighting device 32 can be fully or partially embedded in the filling material 27 as a core light, light guide or light source, with the light then at least partially radiating out of the filling material 27.

[0067] FIG. 3 shows a schematic and sectional view of the composite 16 made up of the decorative cut-out 2 and the functional coating 3, wherein different variants of the through holes 8, 9, 10, 20 are shown using the example of the through holes 8, 20. It can be seen that the through holes 8 of the decorative cut-out 2 and the through hole 15 of the functional coating 3 can at least partially overlap one another, wherein the through holes 8, 15 can differ from one another in terms of geometry and size. In addition, through holes 15 are conceivable in the functional coating which are covered by the decorative cut-out 2, i.e. by one or more of the cut material parts 4, 5, 6, 7. Furthermore, it can be seen (on the far left) that a through hole 15 of the functional coating 3 may not be assigned to a through hole 8 of the decorative cut-out 2. Becauseas already stated abovethe material of the functional coating 3 can be permeable to visible light (indicated in FIG. 3 by dotted arrows).

[0068] In FIG. 3, a use of the functional coating 3 can also be seen, which is or will be formed from a first functional coating 33 and at least one further/second functional coating 34. The functional coating 3 may not be formed in stacks from the functional coatings 33, 34; because it is conceivable that one of the functional coatings 33, 34 is attached or fixed to the visible side 11 of the decorative blank 2, so that the functional coatings 33, 34 are spaced apart from one another in the process via the strength/thickness of the decorative blank 2. The functional coating 3 can be removed from the composite 16 to produce the decorative element 1in particular after filling the through holes 8, 9, 10, 20so that the decorative element 1 no longer has the functional coating 3 or no longer has it completely. It can serve, for example, as a protective element for the visible side 11 and/or as a sealing layer to inhibit the filling material 27 from reaching the visible side 11 when one or more of the through openings 8, 9, 10, 15, 20 are filled. For this purpose, the functional layer 34 can be attached to the visible side 11, for example glued, until the filling material 27 has hardened to such an extent that it is no longer sufficiently flowable to flow onto the visible side 11. This means that, for example, one of the functional coatings 33, 34, two or more of the functional coatings 33, 34 or all of the functional layers 33, 34 can be removed from the composite 16 in order to produce the decorative element 1. In this respect, the connection between the decorative cut-out 2 and the functional layer 3 or the functional coatings 33, 34 is a non-destructively removable fixation, such as a removable adhesive connection or similar. The (respective) functional coating 33, 34 that was removed from the composite 16 can be reused in a new run of the process, e.g. to produce another decorative element 1 in an ecologically favorable manner. In the present case, it is provided that the decorative element 1 has the functional coating 3, e.g. this is not completely removed from the composite 16.

[0069] FIG. 4 shows a schematic and sectional view of the decorative element 1 or the composite 16 from which the decorative element 1 is made, wherein the electrical and/or electronic arrangement 30 of the decorative element 1 is/is fastened in a carrier region 35 of the functional layer 3. The carrier region 35 and the through hole 10, whichfilled with the filling material 27is the light opening 29, are aligned with each another such that the electronic arrangement 30, in particular its light device 32, can have an effect in the light opening 29 and/or through the light opening 29. In other words: the light emerging from the light device 32 (indicated in FIG. 4 by the dotted arrow) filters through the light opening 29, e.g. through the filling material 27, and radiates out of the decorative element 1 on the visible side 11 of the decorative cut-out 2. The situation is analogous if the arrangement 30 has the heating or air conditioning device 31 as an alternative or in addition to the lighting device 32: in this case, the dotted arrow represents a heat radiation or an air-conditioned air flow that exits from the heating/air conditioning device 31, enters the functional opening 28 and then exits from the decorative element 1 on the visible side 11 of the decorative cut-out 2. Accordingly, the arrangement 30 can have a lighting means 36 (e.g. a light source, a light guide element, etc.) and/or a heating/air conditioning means 37 (e.g. an air flow channel, a heating wire, etc.).

[0070] FIG. 5 shows a schematic and sectional view of the decorative element 1, which has a fastening element 38 for the arrangement 30. When producing the decorative element 1, the arrangement 30 and the decorative cut-out 2 and/or the functional coating 3 are fastened to one another by means of the attachment element 38. In the present case, the attachment element 38 has a first fastening unit in the form of a pocket 39, which branches off from the through hole 8, 9, 10, 20 of the decorative cut-out 2. Alternatively or additionally, the fastening element 38 has a further fastening unit (not shown) which branches off from the through hole 15 of the functional layer 3. Furthermore, the arrangement 30 is provided with a fastening flag 40, which corresponds to the pocket 39. The attachment flag can be formed, for example, by a piping flag of a piping, by means of which a light guide is encased. When producing the decorative element 1, which has the arrangement 30, the fastening flag 40 is placed in the pocket 39 and fastened there, in this case by pouring the filling material 27 around the fastening flag 40, i.e. by filling the through-opening 8 of the decorative cut-out 2. In the process, part of the filling material 27 penetrates into the pocket 39 and consequently surrounds the fastening flag 40. Alternatively or additionally, it is conceivable to embroider or sew the arrangement 30 onto the decorative cut-out 2 and/or onto the functional layer 3, to weld it on, to glue it on (with a different/additional adhesive than the filling material 27) and/or other suitable force-, form- and/or material-locking connection or fastening methods.

[0071] FIG. 6 and FIG. 7 each show a schematic and sectional view of the decorative element 1 with the light device 32, which in the present case comprises a light guide 41 that is embedded in the decorative element 1, i.e. in the decorative cut-out 2 and/or in the functional layer 3. It can be seen that, for example, one of the edges 17, 18 or both edges 17, 18 of the decorative cut-out 2 or of the cut material portions 4, 5 have a single-stage or multi-stage cut-out 42, by means of which the light guide 41 is held in position. Alternatively or additionally, the respective annular gap 21, 22 can have the cut-out 42 on its annular gap edges 43, 44. The light device 32, in particular its light guide 41, is held in the cut-out 42 in that the light guide 41 is at least partially arranged in the cut-out 42 and is secured against movement (force-, form- and/or material-locking). According to the example shown in FIG. 6, the functional layer 3 is embedded in the decorative cut-out 2, for example held in the cut-outs 42. It is provided that the functional coating 3 is formed by a textile.

[0072] As a further example and to illustrate that the geometry of the light guide 41 can be freely selected, a further design option is shown in FIG. 7, wherein the decorative cut-out 2 has the cut-outs 42 in an oblique form. The functional layer 3 is formed with oblique edges.

[0073] A schematic and sectional view of the decorative element 1 is shown in FIG. 8, wherein a spacer device 46 with at least one spacer element 47 is formed or attached between the decorative cut-out 2 and the functional layer 3. By means of the spacer elements 47 of the spacer device 46, the fastening sides 12, 13 and consequently the decorative cut-out 2 and the functional layer 3 are spaced apart from one another by a distance 48. The distance 48 provides a construction space 49 between the decorative cut-out 2 and the functional layer 3, which in the present example is used to accommodate elements of the electronic arrangement 30 between the decorative cut-out 2 and the functional layer 3. It is shown in FIG. 8 merely as an example that the heating or air conditioning device 31 and/or lighting device 32 (in each case in whole or in part) can be used in the construction space 49 created or kept free by the distance 48. For example, one of the lighting means 36 and/or one of the heating or air conditioning means 37i.e. a light guide element (in particular the light guide 41), the heating wire, the air flow channel, a conductor track printed on the functional layer, etc.can be accommodated in the construction space 49.

[0074] In FIG. 8, a holding element 45 is also shown, which projects into one of the through holes 8 and in this case is formed in one piece with the functional coating 3. Alternatively, the holding element 45 can be formed separately from the functional layer 3 and arranged on/at the functional layer 3. It can be seen that the holding element 45 is immersed in the through hole 8 or in the functional opening 28. The electronic arrangement 30 is at least partially arranged on an upper side of the holding element 45, in this case by arranging a lighting means 36 and/or a heating or air conditioning means 37 on/at the upper side.

[0075] Overall, the present disclosure is evident in the method for producing the decorative element 1 and through the decorative element 1 itself a respective possibility of how thein particular multifunctionaldecorative element 1 can be produced in a particularly simple or efficient manner, wherein it has at least one functional opening, namely at least one functional opening 28. The decorative element 1 is air-gap-free and offers a significant expansion of the design freedom with regard to a highly integrated and contemporary interior design in the automotive sector. Functions, light representations and light scenarios directly on a surface or visible side of the interior decor according to Digitalization 4.0 offer a particularly advantageous increase in safety and user-friendliness.

[0076] The method and the decorative element enable design freedom for particularly flexible or versatile decorative element concepts with regard to layering arrangements and the introduction of functionalities, in particular multifunctionalities. The individual layers of the decorative element, for example different decorations, number of functional layers and their porosity and mechanical properties, and a number and positional arrangement of the through holes can advantageously be freely combined with one another. An arrangement of openings that are concealed, at least partially not visible from the outside and/or arranged so as to overlap one another (particularly when stacking several functional layers) can also be incorporated into such a combination. Furthermore, variants of the electrical/electronic arrangement, for example sensors, light, light guides, etc., can be added particularly easily to such a combination.

[0077] Unless otherwise expressly indicated herein, all numerical values indicating mechanical/thermal properties, compositional percentages, dimensions and/or tolerances, or other characteristics are to be understood as modified by the word about or approximately in describing the scope of the present disclosure. This modification is desired for various reasons including industrial practice, material, manufacturing, and assembly tolerances, and testing capability.

[0078] As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean at least one of A, at least one of B, and at least one of C.

[0079] In this application, the term controller and/or module may refer to, be part of, or include: an Application Specific Integrated Circuit (ASIC); a digital, analog, or mixed analog/digital discrete circuit; a digital, analog, or mixed analog/digital integrated circuit; a combinational logic circuit; a field programmable gate array (FPGA); a processor circuit (shared, dedicated, or group) that executes code; a memory circuit (shared, dedicated, or group) that stores code executed by the processor circuit; other suitable hardware components (e.g., op amp circuit integrator as part of the heat flux data module) that provide the described functionality; or a combination of some or all of the above, such as in a system-on-chip.

[0080] The term memory is a subset of the term computer-readable medium. The term computer-readable medium, as used herein, does not encompass transitory electrical or electromagnetic signals propagating through a medium (such as on a carrier wave); the term computer-readable medium may therefore be considered tangible and non-transitory. Non-limiting examples of a non-transitory, tangible computer-readable medium are nonvolatile memory circuits (such as a flash memory circuit, an erasable programmable read-only memory circuit, or a mask read-only circuit), volatile memory circuits (such as a static random access memory circuit or a dynamic random access memory circuit), magnetic storage media (such as an analog or digital magnetic tape or a hard disk drive), and optical storage media (such as a CD, a DVD, or a Blu-ray Disc).

[0081] The apparatuses and methods described in this application may be partially or fully implemented by a special purpose computer created by configuring a general-purpose computer to execute one or more particular functions embodied in computer programs. The functional blocks, flowchart components, and other elements described above serve as software specifications, which can be translated into the computer programs by the routine work of a skilled technician or programmer.

[0082] The description of the disclosure is merely exemplary in nature and, thus, variations that do not depart from the substance of the disclosure are intended to be within the scope of the disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure.