阅读说明：本技术 一种汽车内饰氛围灯总成及其制作方法 (Automotive interior atmosphere lamp assembly and manufacturing method thereof ) 是由 夏佩 何娅平 占玉霞 刘强 王鹏 于 2020-04-14 设计创作，主要内容包括：本申请公开了一种汽车内饰氛围灯总成及其制作方法,涉及汽车内饰技术领域,该氛围灯总成包括透光表层,其一侧雕除形成透光图案；发泡层,其设置于透光表层有透光图案的一侧；散光骨架,其通过热熔胶层与发泡层远离透光表层的一侧平整粘接,用于将接收的光线均匀散射；灯壳,其开设有一容纳腔,灯壳扣合于散光骨架远离发泡层的一侧,容纳腔内壁设有用于反射光线的反光层；灯体,其设置于容纳腔内。本申请的汽车内饰氛围灯总成及其制作方法,一方面可实现汽车内饰氛围灯总成软触的质感效果,另一方面,在点亮氛围灯时,也可保证氛围灯的发光效果,满足客户需求；还可进一步提升氛围灯的整体亮度,以及氛围灯总成的透光率均匀度。(The application discloses an automotive interior atmosphere lamp assembly and a manufacturing method thereof, and relates to the technical field of automotive interior, the atmosphere lamp assembly comprises a light-transmitting surface layer, and a light-transmitting pattern is formed by carving and removing one side of the light-transmitting surface layer; the foaming layer is arranged on one side of the light-transmitting surface layer with the light-transmitting patterns; the light scattering framework is flatly adhered to one side, away from the light-transmitting surface layer, of the foaming layer through the hot melt adhesive layer and is used for uniformly scattering received light; the lamp shell is provided with an accommodating cavity, the lamp shell is buckled on one side of the light scattering framework, which is far away from the foaming layer, and the inner wall of the accommodating cavity is provided with a reflecting layer for reflecting light; the lamp body, it sets up in holding the intracavity. According to the automotive interior atmosphere lamp assembly and the manufacturing method thereof, on one hand, the soft touch texture effect of the automotive interior atmosphere lamp assembly can be realized, on the other hand, the light-emitting effect of the atmosphere lamp can be ensured when the atmosphere lamp is lightened, and the requirements of customers are met; the overall brightness of the atmosphere lamp and the light transmittance uniformity of the atmosphere lamp assembly can be further improved.)

1. An automotive interior atmosphere lamp assembly, comprising:

a light-transmitting surface layer (1) with one side engraved with a light-transmitting pattern (2);

a foaming layer (3) arranged on one side of the light-transmitting surface layer (1) with the light-transmitting pattern (2);

the light scattering framework (5) is flatly adhered to one side, far away from the light-transmitting surface layer (1), of the foaming layer (3) through a hot melt adhesive layer (4) and is used for uniformly scattering received light;

the lamp shell (6) is provided with an accommodating cavity, the lamp shell (6) is buckled on one side, away from the foaming layer (3), of the light scattering framework (5), and a reflecting layer for reflecting light is arranged on the inner wall of the accommodating cavity;

and the lamp body (7) is arranged in the accommodating cavity.

2. The automotive interior mood lamp assembly of claim 1, wherein: a paint layer is formed on one side, close to the foaming layer (3), of the light-transmitting surface layer (1), the thickness of the paint layer is 20-30 mu m, and the paint layer is carved and removed through laser to form the light-transmitting pattern (2).

3. The automotive interior mood lamp assembly of claim 1, wherein: the light-transmitting surface layer (1) is made of PV leather or PVC leather, and the light transmittance is 5-20%.

4. The automotive interior mood lamp assembly of claim 1, wherein: the light scattering framework (5) is made of a light-transmitting material with 75% -95% of light transmittance, and the light-transmitting material comprises a resin base material, and a light diffusant and an auxiliary agent which are dispersed in the resin base material.

5. A method of making an automotive interior mood light assembly as recited in claim 1, comprising the steps of:

carving the light-transmitting surface layer (1) to form a light-transmitting pattern (2);

fixing and molding one side of the light-transmitting surface layer (1) with the light-transmitting pattern (2) and the foaming layer (3);

coating a hot melt adhesive layer (4) on the light scattering framework (5), flatly bonding one side of the light scattering framework (5) coated with the hot melt adhesive layer (4) with the foaming layer (3), and performing pressure composite molding;

and a reflective layer is formed on the inner wall of the accommodating cavity of the lamp shell (6), the lamp body (7) is installed in the accommodating cavity, and one side of the light scattering framework (5) far away from the foaming layer (3) is buckled in the accommodating cavity.

6. The method according to claim 5, wherein the engraving of the light-transmissive surface layer (1) to form the light-transmissive pattern (2) specifically comprises:

forming a paint layer on the light-transmitting surface layer (1);

and carrying out laser engraving removal on the paint layer to ensure that the engraved part is called as a light-transmitting part, so as to form a light-transmitting pattern (2).

7. The method according to claim 5, wherein the step of applying the hot-melt adhesive layer (4) on the light scattering skeleton (5) comprises:

heating the hot melt adhesive particles to a molten state;

injecting a hot melt adhesive in a molten state into a roller, wherein the surface of the roller is provided with glue spraying holes, and the length of the roller is greater than or equal to the width of the light scattering framework (5);

the roller is attached to the light scattering framework (5) for blade coating, the light scattering framework (5) is filled through hot melt adhesive, and a hot melt adhesive layer (4) with a smooth surface is formed; the thickness of the hot melt adhesive layer (4) is 80-100 mu m.

8. The method according to claim 7, wherein after the step of forming the hot-melt adhesive layer (4) with a flat surface, the method further comprises the following steps:

and cutting off redundant hot melt adhesive at the edge of the light scattering framework (5).

9. The method of claim 8,

the side, coated with the hot melt adhesive layer (4), of the light scattering framework (5) is flatly bonded with the foaming layer (3) and is formed by pressure compounding, and the method specifically comprises the following steps:

placing the light scattering framework (5) coated with the hot melt adhesive layer (4) in a constant temperature box, and heating until the bonding performance of the hot melt adhesive layer (4) is in an activated state;

and flatly sticking the foaming layer (3) fixed with the light-transmitting surface layer (1) on the surface of the hot-melt adhesive layer (4) of the light-scattering framework (5), and performing pressure composite molding through a pressing mold.

10. The method of manufacturing of claim 5, wherein: the light scattering framework (5) is made of a light-transmitting material with 75% -95% of light transmittance, and the light-transmitting material comprises a resin base material, and a light diffusant and an auxiliary agent which are dispersed in the resin base material.

Technical Field

The application relates to the technical field of automotive interior, in particular to an automotive interior atmosphere lamp assembly and a manufacturing method thereof.

Background

Along with the continuous promotion of each aspect performance requirement of automobile products to and the popularization of car intelligence passenger cabin function, user science and technology experience has obtained showing the promotion, and each big host computer factory and spare part supplier also pay attention to intelligent passenger cabin day by day, and automotive interior intelligence atmosphere lamp technical application scope is more and more wide.

Along with the research and development application of the new material printing opacity epidermis of intelligent surface interior trim, provided new demand to the atmosphere lamp, can realize the atmosphere lamp effect night promptly, the feel effect of soft touch can be realized on the atmosphere lamp surface during daytime or light-tight to reduce interior trim plastics and feel.

The interior atmosphere lamp assembly used for mass production vehicle type at present has two main structures. One type of atmosphere lamp transmits light through gaps formed among components of an interior trim, but is limited by multilayer overlapping of parts and limitation of light transmittance of materials, the light transmittance of an atmosphere lamp assembly is poor, and patterns are not clearly displayed; the other is to transmit light through a single layer of rigid plastic, but the requirements of the atmosphere lamp at present cannot be met.

Disclosure of Invention

Aiming at one of the defects in the prior art, the application aims to provide the automotive interior atmosphere lamp assembly and the manufacturing method thereof, so that the soft touch texture effect and the overall brightness of the automotive interior atmosphere lamp assembly are ensured, and meanwhile, the light transmittance uniformity of the automotive interior atmosphere lamp assembly can be improved.

In a first aspect, an automotive interior mood lamp assembly is provided that includes:

a light-transmitting surface layer, one side of which is carved out to form a light-transmitting pattern;

a foaming layer arranged on one side of the light-transmitting surface layer with the light-transmitting pattern;

the light scattering framework is flatly adhered to one side, far away from the light-transmitting surface layer, of the foaming layer through a hot melt adhesive layer and is used for uniformly scattering received light;

the lamp shell is buckled on one side of the light scattering framework, which is far away from the foaming layer, and the inner wall of the accommodating cavity is provided with a reflecting layer for reflecting light;

and the lamp body is arranged in the accommodating cavity.

In some embodiments, a paint layer is formed on a side of the light-transmitting surface layer close to the foam layer, the paint layer has a thickness of 20-30 μm, and the paint layer is laser-engraved to form the light-transmitting pattern.

In some embodiments, the light transmissive skin layer is made of PV leather or PVC leather and has a light transmission of 5-20%.

In some embodiments, the light scattering skeleton is made of a light-transmitting material with 75% -95% light transmittance, and the light-transmitting material comprises a resin base material, and a light diffusing agent and an auxiliary agent which are dispersed in the resin base material.

In a second aspect, a method for manufacturing the automotive interior atmosphere lamp assembly is provided, which includes the steps of:

carving the light-transmitting surface layer to form a light-transmitting pattern;

fixing and molding one side of the light-transmitting surface layer with the light-transmitting pattern with the foaming layer;

coating a hot melt adhesive layer on the light scattering framework, flatly bonding one side of the light scattering framework coated with the hot melt adhesive layer with a foaming layer, and performing pressure composite molding;

and a reflecting layer is formed on the inner wall of the accommodating cavity of the lamp shell, the lamp body is arranged in the accommodating cavity, and one side of the light scattering framework, which is far away from the foaming layer, is buckled in the accommodating cavity.

In some embodiments, the engraving the light-transmitting surface layer to form the light-transmitting pattern specifically includes:

forming a paint layer on the light-transmitting surface layer;

and carrying out laser engraving removal on the paint layer to ensure that the engraved part is called as a light-transmitting part, so as to form a light-transmitting pattern.

In some embodiments, the coating of the hot melt adhesive layer on the light scattering skeleton specifically includes:

heating the hot melt adhesive particles to a molten state;

injecting the hot melt adhesive in a molten state into a roller, wherein the surface of the roller is provided with glue spraying holes, and the length of the roller is greater than or equal to the width of the light scattering framework;

the roller is attached to the light scattering framework for blade coating, the light scattering framework is filled by hot melt adhesive, and a hot melt adhesive layer with a smooth surface is formed; the thickness of the hot melt adhesive layer is 80-100 μm.

In some embodiments, after the forming of the hot melt adhesive layer with a flat surface, the method further includes:

and cutting off the residual heat molten glue at the edge of the astigmatic framework.

In some embodiments, the side of the light scattering skeleton coated with the hot melt adhesive layer is flatly bonded with the foaming layer, and is formed by pressure composite molding, which specifically comprises:

placing the light scattering framework coated with the hot melt adhesive layer in a constant temperature box, and heating until the bonding performance of the hot melt adhesive layer is in an activated state;

and flatly sticking the foaming layer fixed with the light-transmitting surface layer to the surface of the hot melt adhesive layer of the light scattering framework, and performing pressure composite molding through a press mold.

In some embodiments, the light scattering skeleton is made of a light-transmitting material with 75% -95% light transmittance, and the light-transmitting material comprises a resin base material, and a light diffusing agent and an auxiliary agent which are dispersed in the resin base material.

The beneficial effect that technical scheme that this application provided brought includes:

the embodiment of the application provides an automotive interior atmosphere lamp assembly, wherein a light-transmitting pattern is formed by carving on one side of a light-transmitting surface layer, and the light-transmitting pattern is positioned on one side, close to a lamp body, of the light-transmitting surface layer, so that on one hand, the soft touch texture effect of the automotive interior atmosphere lamp assembly can be realized, and on the other hand, when an atmosphere lamp is lightened, the light-emitting effect of the atmosphere lamp can be ensured, and the requirements of customers are met; the light emitted by the lamp body is reflected by arranging the reflecting layer on the inner wall of the accommodating cavity, so that the overall brightness of the atmosphere lamp can be improved; the astigmatism skeleton passes through the hot melt adhesive layer and levels the bonding with the foaming layer, can improve the luminousness degree of consistency of atmosphere lamp assembly.

Drawings

FIG. 1 is a schematic view of an automotive interior mood light assembly according to an embodiment of the present application;

FIG. 2 is a schematic view of a light transmissive pattern according to an embodiment of the present application;

FIG. 3 is a flow chart illustrating a method for manufacturing an automotive interior mood light assembly in accordance with an embodiment of the present disclosure;

fig. 4 is a schematic view of coating a hot melt adhesive layer on the light scattering skeleton according to the embodiment of the present application.

In the figure: the LED lamp comprises a transparent surface layer 1, a transparent pattern 2, a foaming layer 3, a hot melt adhesive layer 4, a light scattering framework 5, a lamp shell 6, a lamp body 7 and a roller 8.

Detailed Description

The present application will be described in further detail with reference to the accompanying drawings and examples.

Referring to fig. 1, the present application provides an embodiment of an automotive interior lamp assembly comprising a light transmissive skin layer 1, a foam layer 3, a light diffusing skeleton 5, a lamp housing 6, and a lamp body 7.

One side of the light-transmitting surface layer 1 is carved out to form a light-transmitting pattern 2. The foaming layer 3 is disposed on the side of the light-transmitting surface layer 1 having the light-transmitting pattern 2. The light scattering framework 5 is flatly bonded with one side, far away from the light-transmitting surface layer 1, of the foaming layer 3 through the hot melt adhesive layer 4, and the light scattering framework 5 is used for uniformly scattering received light. The light-transmitting surface of the atmosphere lamp is formed by the light-transmitting surface layer 1, the foaming layer 3 and the light-scattering framework 5.

The lamp housing 6 is provided with a containing cavity, the lamp housing 6 is buckled on one side of the light scattering framework 5 far away from the foaming layer 3, and the inner wall of the containing cavity is provided with a reflecting layer for reflecting light. The lamp body 7 is disposed in the accommodating chamber.

In the embodiment, the light-transmitting pattern is formed by engraving and removing one side of the light-transmitting surface layer, and the light-transmitting pattern is positioned on one side of the light-transmitting surface layer close to the lamp body, so that on one hand, the soft touch texture effect of the automotive interior atmosphere lamp assembly can be realized, and on the other hand, when the atmosphere lamp is lighted, the light-emitting effect of the atmosphere lamp can be ensured, and the requirements of customers are met; the light emitted by the lamp body is reflected by arranging the reflecting layer on the inner wall of the accommodating cavity, so that the overall brightness of the atmosphere lamp can be improved; the astigmatism skeleton passes through the hot melt adhesive layer and levels the bonding with the foaming layer, can improve the luminousness degree of consistency of atmosphere lamp assembly.

In addition to the above embodiments, in this embodiment, a paint layer is formed on the side of the light-transmitting surface layer 1 close to the foaming layer 3, the thickness of the paint layer is 20-30 μm, and the paint layer is laser-engraved to form the light-transmitting pattern 2. Optionally, the paint layer is engraved in the desired pattern by computer programmed control.

Specifically, the paint layer is through the partial printing opacity that the laser carving removed, and the part that the paint layer was not carved to remove is light tight, and the light that lamp body 7 sent passes along the part that the laser carving removed, and then forms printing opacity pattern 2, realizes the purpose of baking the support atmosphere.

Referring to fig. 2, in the present embodiment, the light-transmitting portion is a light-transmitting region, and the light-opaque portion is a light-opaque region. Optionally, the light-transmitting area includes a plurality of rectangular holes distributed in rows and columns, and the plurality of rectangular holes are embedded in the light-blocking area to form the corresponding light-transmitting patterns 2. According to the requirement of pattern size, a is the width of a single rectangular hole, b is the length of the single rectangular hole, d is the distance between adjacent rectangular holes in each row of rectangular holes, and L is the distance between the edge of the light-transmitting pattern 2 and the closest rectangular hole. Wherein a is more than or equal to 2mm, b is more than or equal to 2mm, d is more than or equal to 4mm, and L is more than 10mm, so that a light-transmitting pattern can not appear in the covering area of the other side of the light-diffusing framework 5 after the light-transmitting surface layer 1 is coated on the light-diffusing framework 5, namely the other side of the light-diffusing framework 5 can not transmit light.

Preferably, the light-transmitting surface layer 1 is made of PV leather or PVC leather, and the light-transmitting surface layer 1 is in a semi-light-transmitting form and has a light transmittance of 5-20%. When the whole shading or the light source is not turned on, the appearance of the light-transmitting surface layer 1 is consistent with that of the conventional leather, and normal color textures are displayed; when the lamp body 7 emits light, the light-transmitting surface layer 1 can transmit light, and can display atmosphere lamp patterns with adjustable colors, so that the definition and the brightness of the patterns are ensured.

Optionally, the 3 foaming layers are made of 3D mesh (3D mesh) material or fabric material with high light transmittance.

On the basis of the second embodiment, in this embodiment, the light scattering skeleton 5 is made of a light transmitting material with 75% -95% light transmittance, and the light transmitting material includes a resin base material, and a light diffusing agent and an auxiliary agent dispersed in the resin base material. The resin base material can meet the flame retardance, hardness and toughness of the light scattering framework; the light diffusion agent and the auxiliary agent which are dispersed in the resin base material can realize the effects of high light transmittance of the light diffusion framework and uniform light source scattering.

Further, transparent PC (Polycarbonate) may be used as the resin base material, and a light diffusing agent may be added thereto in a predetermined ratio by optical design. Wherein, the light diffusion agent can be acrylic type, styrene type or acrylic resin type, and other auxiliary agents comprise stabilizer, antioxidant, flame retardant and the like. The PC base material, the light diffusion agent and the auxiliary agent are subjected to a polymerization process to obtain light-transmitting and opaque light diffusion material particles, and the light diffusion material particles are subjected to injection molding to obtain the light scattering framework 5, so that the light scattering framework 5 has the physical properties of the PC material and has high light transmittance.

In this embodiment, the lamp housing 6 is made of a black material so as to shield light, but the black material itself has light absorption property, which easily causes the loss of brightness of the light source. The light emitted by the lamp body 7 can be reflected by arranging the reflecting layer on the inner wall of the accommodating cavity so as to improve the brightness of the lamp body 7. Wherein, the reflecting layer is made of reflecting materials.

Referring to fig. 3, the application further provides a manufacturing method based on the automotive interior atmosphere lamp assembly, which includes the steps of:

s1, carving the light-transmitting surface layer 1 to form a light-transmitting pattern 2.

S2, fixing and forming one side of the light-transmitting surface layer 1 with the light-transmitting pattern 2 and the foaming layer 3.

S3, coating a hot melt adhesive layer 4 on the light scattering framework 5, flatly bonding one side of the light scattering framework 5 coated with the hot melt adhesive layer 4 with the foaming layer 3, and performing pressure composite molding.

And S4, forming a reflective layer on the inner wall of the accommodating cavity of the lamp shell 6, installing a lamp body 7 in the accommodating cavity, and buckling one side of the light scattering framework 5, which is far away from the foaming layer 3, in the accommodating cavity.

On the basis of the foregoing embodiment, in this embodiment, the step S1 specifically includes:

first, a paint layer is formed on the light-transmitting surface layer 1. The paint layer is a black paint layer.

Then, the paint layer is laser-engraved, and the engraved portion is referred to as a light-transmitting portion, thereby forming the light-transmitting pattern 2.

Finally, a layer of varnish is sprayed on the whole surface of the light-transmitting surface layer 1 forming the light-transmitting pattern 2, so that the hardness of the surface of the light-transmitting surface layer 1 is ensured, and a paint layer is protected.

Referring to fig. 4, on the basis of the above embodiment, in this embodiment, the step S3 of coating the hot melt adhesive layer 4 on the light scattering skeleton 5 specifically includes:

first, transparent hot melt adhesive particles are heated to a molten state.

And then, injecting the hot melt adhesive in a molten state into the roller 8, wherein the hot melt adhesive can be stored in the roller 8, the surface of the roller 8 is provided with an adhesive spraying hole, and the length of the roller 8 is greater than or equal to the width of the light scattering framework 5.

In this embodiment, spout the gluey hole and be equipped with two sets ofly, two sets ofly spout gluey hole along cylinder 8's circumference parallel arrangement. Each group of glue spraying holes are arranged along the axial direction of the roller 8, and the interval between two adjacent glue spraying holes is 20 mm. Optionally, the diameter of the single glue spraying hole is 5-10 mm.

Finally, the roller 8 with the hot melt adhesive stored therein is smoothly attached to the surface of the light scattering framework 5, so that the attachment gap between the roller 8 and the light scattering framework 5 is ensured to be zero as much as possible. The roller 8 is fixed by a mechanical clamping mechanism, so that the roller 8 is pressed on the astigmatic framework 5 with a certain pressing force, and is subjected to rolling blade coating along the length direction of the astigmatic framework 5. The roller 8 uniformly coats the hot melt adhesive on the surface of the light scattering framework 5 in a rolling way, and the rolling and coating times are 2-3. The light transmittance of the hot melt adhesive coating is greater than or equal to 60%.

Can fill up the tiny pothole or gap in above-mentioned astigmatism skeleton 5 surface through the hot melt adhesive, get rid of the air between astigmatism skeleton 5 and the hot melt adhesive layer 4, guarantee the laminating between astigmatism skeleton 5 and the hot melt adhesive layer 4 to form level and smooth and even hot melt adhesive layer 4 of thickness. The thickness of the hot melt adhesive layer 4 is 80-100 μm, and the thickness error is controlled within +/-10 μm. In this embodiment, the thickness of the hot melt adhesive layer 4 is 90 μm.

Preferably, in step S3, after the hot melt adhesive layer 4 with a flat surface is formed, the method further includes:

and (3) inspecting the surface of the light scattering framework 5, and cutting off redundant hot melt adhesive at the edge of the light scattering framework 5.

Further, in the step S3, the side of the light scattering skeleton 5 coated with the hot melt adhesive layer 4 is flatly adhered to the foaming layer 3, and is formed by pressure compounding, which specifically includes:

firstly, putting the light scattering framework 5 coated with the hot melt adhesive layer 4 in a constant temperature box for heating until the bonding performance of the hot melt adhesive layer 4 is in an activated state.

Then, the foaming layer 3 fixed with the light-transmitting surface layer 1 is flatly adhered to the surface of the hot melt adhesive layer 4 of the light scattering framework 5, and is subjected to pressure composite molding through a pressing mold.

On the basis of the above embodiment, in this embodiment, the light scattering skeleton 5 is made of a light-transmitting material with 75% to 95% of light transmittance, and the light-transmitting material includes a resin base material, and a light diffusing agent and an auxiliary agent dispersed in the resin base material.

In this embodiment, the lamp body 7 is an LED bulb, and provides a direct light source through the LED bulb, and realizes that the light source is multi-color adjustable, thereby avoiding a side projection light source, and ensuring the brightness of the light source.

The manufacturing method of the embodiment is suitable for the automotive interior atmosphere lamp assemblies, not only can the soft touch effect on the surface of the atmosphere lamp be realized, but also the higher light transmittance uniformity of the atmosphere lamp, clear light-transmitting patterns and the qualified brightness can be ensured when the lamp body 7 is lightened under the conventional power.

The present application is not limited to the above embodiments, and it will be apparent to those skilled in the art that various modifications and improvements can be made without departing from the principle of the present application, and such modifications and improvements are also considered to be within the scope of the present application.