Method for producing a component with a flat decorative element and component with a flat decorative element

The invention relates to a method for producing a component according to the preamble of claim 1.

Components with a flat decorative element are known in particular in the automotive industry. For example, the<patcit id="pcit0001" dnum="DE4421942C2"><text>DE 44 21 942 C2</text></patcit> a component which has an illuminable field such as a lettering or a symbolism and which is provided as a door sill or entry rail for a vehicle. The sheet-like decorative element is formed by a wall portion having openings made by lasering, stamping or the like. On a rear side of the wall part, a luminous film is attached. Between this luminous film and the wall part, an intermediate part made of a translucent plastic is arranged. This intermediate part has elevations, which protrude into said openings. This intermediate part is fastened for example by gluing or screwing on the wall part.

The <patcit id="pcit0002" dnum="DE202004008681U1"><text>DE 20 2004 008 681 U1</text></patcit> discloses a component provided for a floor pan edge of an automobile. Here, too, an intermediate part is provided which has elevations which engage in corresponding openings of the flat decorative element. Also provided is a light source on the back of the decorative element. A decorative body with illuminated decorative elements is also from the<patcit id="pcit0003" dnum="EP2028048A1"><text>EP 2 028 048 A1</text></patcit> known.

The <patcit id="pcit0004" dnum="US6419306A"><text>US 6,419,306 A</text></patcit> discloses an illuminable panel for motor vehicles having a sheet-like decorative element with apertures, a multilayer film and a light guide. To get a flat visible side, the openings are filled with transparent plastic.

If a component is to be produced with a lettering having, for example, the letters A and B, these letters each contain at least one island-shaped part which must be positioned accordingly. This is possible for example by webs. But such webs are often not desired, for example, for aesthetic reasons. The positioning of these island-shaped parts in the injection molding tool by means of vacuum is known. However, this is relatively expensive. In addition, the island-shaped parts must be positioned in recesses of the injection molding tool, which can be done with a gripper or by hand. It has also been shown that the aforementioned island-shaped parts on the finished manufactured component are not always exactly flush with the surface of the flat decorative element.

The invention has for its object to provide a method of the type mentioned that allows easier production of such a component.

The object is achieved in a generic method according to claim 1.

In the method according to the invention, the at least one breakthrough is at least partially and preferably completely filled by the foil. If an island-like part is covered, it is fixed by the film before the at least one layer is applied. A further advantage is that the at least one island-shaped part is positioned particularly securely by the engagement of the foil in the at least one opening and that external influences such as temperature changes and moisture can not influence the exact positioning of the island-shaped part. This can be additionally improved by engaging the at least one layer in the film. Preferably, the film is flush to the visible side. Since the decorative element is not injected directly behind, but the film is injected, the injection point can be freely selected. This could also be in the area of ​​an island-shaped part, since this part is protected by the film and in particular displacements of the part can be avoided by the Anspritzdruck.

It has been found that the method according to the invention has the particular advantage that the foil which has penetrated into the at least one breakthrough removes or makes ineffective sharp edges of the sheetlike decorative element in the region of the at least one opening. Gaps in the region of the at least one breakthrough can be avoided, so that contamination can be avoided even with prolonged use. The inventive method is therefore also suitable for producing a component in which the flat decorative element has no island-shaped parts.

In particular, the method is suitable for producing a component with which an illuminable field in the interior or exterior of a motor vehicle can be produced. For example, but not exclusively, such a component is suitable for producing a door sill, a decorative strip, an operating element, for example a button.

According to a development of the invention it is provided that the film is adhered to the back of the sheet-like decorative element. The sticking of the film can be done particularly easily and safely by means of a roller. On the film and / or the decorative element, a bonding agent can be applied.

The film is in particular a plastic film. This can be colorless or white or colored. By colored plastic films correspondingly colorful illuminated fields can be produced. The film may be single or multi-layered. The at least one film is at least partially translucent. It is also conceivable embodiment with multiple slides, which may be the same or different.

The at least one layer is produced according to an embodiment of the invention by injection molding or extrusion. In all these cases, a pressure is exerted on the film by which an area of ​​the film is pressed into the at least one opening and finally engages at least partially into it. The at least one layer preferably again engages in the film. Finally, a very stable composite of at least three layers is obtained. Preference is given to the production by injection molding, since there are essentially no restrictions with respect to the shape of the component, whereas components produced by extrusion must be substantially band-shaped. Also possible is injection-compression molding, which is a form of injection molding.

The flat decorative element is made according to an embodiment of the invention of a metal sheet. In principle, however, the two-dimensional decorative element could also be made of plastic, for example. The plastic decorative element may be at least partially translucent. The decorative element may be a very thin and highly flexible film, since the decorative element is carried by the example molded plastic layer. The plastic layer may be provided with fastening parts with which the component can be attached.

According to a development of the invention, it is provided that the at least one island-shaped part is fixed in a receptacle by means of vacuum before the film is applied. After the application of the film, the vacuum can be canceled and the flat decorative element with the film, for example, be inserted into the mold cavity of an injection molding tool. In the injection molding tool or in the extruder then a fixation of the island-shaped part is no longer mandatory.

The inventive component produced by the process has at least three layers. The first layer is formed by the sheet-like decorative element and the second layer by the film applied to the back of this decorative element. The film engages in the area of ​​the openings in this and thus at least partially fills these openings. On the visible side of the component, the film in the region of the openings is preferably flush with this visible side. This visible side forms with the possibly existing island-shaped parts a plane or even uneven, for example, curved surface, outside the at least one breakthrough are of course also surveys or depressions conceivable. Such a component may have a comparatively small thickness of a few millimeters. In particular, the sprayed-on layer is a load-bearing layer provided with fastening parts, while the decorative element can be very thin and flexible. In particular, it can be ensured that island-shaped parts are flush with respect to the visible side.

At the back of the component, for example, a light guide may be present, on which a light source is arranged. The light source may be formed by one or more LEDs. Also possible is a lighting only with LEDs or an electroluminescent film. The inventive component is intended in particular for the automotive industry, but there are also applications in other areas conceivable. For example, such a component could be used to produce an illuminated field in a piece of furniture or a household appliance, for example refrigerators, steamer, washing machines, ovens, cooking stoves or dishwashers.

Further advantageous features emerge from the dependent claims, the following description and the drawings.

Embodiments of the invention will be explained in more detail with reference to the drawing. Show it:<dl id="dl0001" compact="compact"><dt>Fig. 1</dt><dd>3 is a schematic view of a component according to the invention;</dd><dt>Fig. 2</dt><dd>a section through a portion of the sheet-like decorative element,</dd><dt>Fig. 3</dt><dd>a section according to <figref idref="f0001">Fig. 2</figref>, wherein on the flat decorative element on the back a foil is applied,</dd><dt>Fig. 4</dt><dd>a section through the inventive component along the line IV - IV of <figref idref="f0002">Fig. 5</figref>.</dd><dt>Fig. 5</dt><dd>a view of a portion of the visible side of a device according to the invention and</dd><dt>Fig. 6 to 8</dt><dd>Partial sections through variants of the inventive component.</dd></dl>

The <figref idref="f0001">Fig. 1</figref> shows a component 1, which has a flat or uneven viewing side 2, on which a field 3 is visible, which represents the letters A, B and C. These letters are here only an example of such a field, which can be configured as desired. The field 3 is illuminated. The lighting means required for this purpose are not shown here, but those skilled in the art are known per se.

Field 3 is represented by the in <figref idref="f0001">Fig. 2</figref> shown openings 6 formed in a flat decorative element 4. These openings 6 are produced for example by laser or punching. The flat decorative element 4 is for example a metal sheet, for example made of aluminum. Basically, the flat decorative element 4 but could also be made of other material, for example made of plastic. Preferably, the flat decorative element 4 has a comparatively small thickness of, for example, one millimeter or less than one millimeter, preferably less than 0.5 millimeter. The flat decorative element 4 may be covered with a protective film, which is usually removed after installation.

The flat decorative element 4 has a back 5, on which a film 8 is applied flat. This film 8 forms a preferably translucent or at least partially transparent layer of plastic. The thickness of the film 8 or layer is preferably one millimeter or less than one millimeter, and preferably more than 0.05 millimeter. The thickness is preferably 0.1 to 0.3 millimeters. The film 8 is made for example of ABS, polycarbonate or PMMA.

The component 1 has a further layer 11, which is formed by a thermoplastic material, which is molded onto a rear side 10 of the film 8. In the area of ​​the apertures 6, the film 8 is pressed through the layer 11 into these apertures 6. The film 8 thus has according to<figref idref="f0002">Fig. 4</figref> Areas 8 ', which are visible on the visible side 2. These areas 8 'are flush with respect to the visible side 2. The areas 8 'fill the openings 6 completely. In particular, by the regions 8 'edges 13 (<figref idref="f0001">Fig. 3</figref> and <figref idref="f0002">4</figref>) in the openings 6 through the areas 8 'covered. The sharpness of these edges 13 is thus eliminated by the areas 8 'and also form at these edges 13 no gaps through which parts or liquid could penetrate. However, the film 8 may also project on the visible side 2. The film 8 may form, for example on the visible side projecting nubs 14, as the<figref idref="f0003">Fig. 6</figref> shows. This in<figref idref="f0003">Fig. 6</figref> shown component 1 ', has a film 8', which completely fills the opening 6 and also on a visible side 2 'protrudes and the nubs 14 forms. As can be seen, the layer 11 engages in the film 8 'in the region of the aperture 6 with a likewise knob-shaped region 11a.

The <figref idref="f0003">Fig. 7</figref> shows a component 1 ", in which a film 8" with respect to a visible side 2 "flush, the opening 6 but not completely fills, so that on the visible side 2" between the film 8 "and the decorative element 4, a gap 15 is present. At the in <figref idref="f0003">Fig. 8</figref> shown component 1 "'engages a film 8"' in the opening 6, but is not flush with a visible side 2 '"and also forms a gap 15th

The invention thus enables the production of components 1 to 1 "'with substantially different visible sides 2 to 2'".

The layer 11 and the film 8 are translucent or transparent, so that the field 3 can be illuminated from a rear side 12 forth. The layer 11 may have attachment means, not shown here, with which the component can be attached, for example, to a body of a motor vehicle.

In field 3, according to the <figref idref="f0001">FIGS. 1</figref> and <figref idref="f0002">5</figref> island-shaped parts 7 and 7 'present. These parts 7 and 7 'are according to<figref idref="f0002">Fig. 4</figref> embedded in the film 8 and are thus fixed by this. These island-shaped parts 7 are preferably flush with respect to the visible side 2.

Hereinafter, the preferred method for producing the component 1 will be explained in more detail.

In a first step, the flat decorative element 4 is made for example of a band-shaped material. The openings 6 are produced, for example, by laser or punching. The flat decorative element 4 is in this case fixed in a receptacle, not shown here. The fixation is effected for example by a vacuum which is applied to the visible side 2. The island-shaped parts 7 produced during the production of the apertures 6 are likewise fixed by the vacuum.

In a second step, the film 8 is applied to the back 5. The film 8 is preferably adhered to the back 5. The film 8 and / or the flat decorative element 4 are in this case provided with an adhesive layer or adhesive parts, not shown here. The sticking or applying the film 8 takes place here, for example, with a role not shown here. If the film 8 is applied to the decorative element 4, then the decorative element 4 is removed from the receptacle. Island-shaped parts 7 and 7 'are now fixed by the film 8.

The provided with the film 8 surface decorative element 4 is now inserted into a mold cavity of an injection molding tool, not shown here. The injection molding tool may be formed as usual. After closing the injection molding tool, the layer 11 is produced by injection-molding of the inserted part. Due to the injection pressure, the film 8 is deformed in the region of the apertures 6 and penetrates into the apertures 6. Accordingly, the layer 11 penetrates in the region of the apertures 6 in the film 8, as the<figref idref="f0002">Fig. 4</figref> lets recognize. The component 1 can now be removed from the mold.

The layer 11 can alternatively be produced by extrusion. The flat decorative element 4 is hereby pulled with the applied film 8 through an extrusion die and in this case the layer 11 is applied continuously. The flat decorative element 4 and the film 8 in this case form a band. It is also possible to produce the layer 11 by injection-compression molding, which is also an injection molding process.

LIST OF REFERENCE NUMBERS

<dl id="dl0002" compact="compact"><dt>1</dt><dd>component</dd><dt>2</dt><dd>Main page</dd><dt>3</dt><dd>field</dd><dt>4</dt><dd>flat decorative element</dd><dt>5</dt><dd>back</dd><dt>6</dt><dd>breakthroughs</dd><dt>7</dt><dd>island-shaped part</dd><dt>8th</dt><dd>foil</dd><dt>9</dt><dd>previous page</dd><dt>10</dt><dd>back</dd><dt>11</dt><dd>layer</dd><dt>12</dt><dd>back</dd><dt>13</dt><dd>edge</dd><dt>14</dt><dd>burl</dd><dt>15</dt><dd>gap</dd></dl>