阅读说明：本技术 可选择性照明的金属外观装饰件以及其制造方法 (Selectively illuminable metal-looking decorative piece and manufacturing method thereof ) 是由 塞尔吉奥·皮尔斯 胡安·蒙莱昂 于 2019-10-25 设计创作，主要内容包括：一种用于对象的装饰件以及其制造方法涉及提供限定顶部表面的透明或半透明基底,将不透明层施加到该基底的顶部表面上方,该不透明层限定光能够穿过的一个或多个孔,以及将一个或多个半透明金属外观层施加到该不透明层的顶部表面上方。在一些具体实施中,该装饰件为可选择性照明的装饰件,由此光源被布置在该基底的底部表面下方,该光源被配置为将光输出穿过该基底、由该不透明层限定的一个或多个孔以及该一个或多个金属外观层。(A trim piece for an object and a method of making the same involves providing a transparent or translucent substrate defining a top surface, applying an opaque layer over the top surface of the substrate, the opaque layer defining one or more holes through which light can pass, and applying one or more semi-transparent metal appearance layers over the top surface of the opaque layer. In some implementations, the trim piece is a selectively illuminable trim piece, whereby a light source is disposed below a bottom surface of the substrate, the light source configured to output light through the substrate, the one or more apertures defined by the opaque layer, and the one or more metal appearance layers.)

1. A trim for an object, the trim comprising:

a transparent or translucent substrate defining a top surface;

an opaque layer applied over the top surface of the substrate, the opaque layer defining one or more apertures through which light can pass; and

one or more semi-transparent metallic look layers applied over a top surface of the opaque layer.

2. The trim of claim 1, further comprising a first translucent primer layer applied to the top surface of the substrate, wherein the opaque layer is applied to a top surface of the first translucent primer layer.

3. The trim of claim 2, further comprising a second translucent primer layer applied to portions of the top surface of the first translucent primer layer corresponding to the one or more holes and the top surface of the opaque layer, wherein the one or more translucent metal appearance layers are applied to a top surface of the second translucent primer layer.

4. The trim of claim 3, further comprising a topcoat layer applied to a top surface of the one or more metallic appearance layers.

5. The trim of claim 1, further comprising a topcoat layer applied to a top surface of the one or more metallic appearance layers.

6. The trim of claim 2, further comprising a topcoat layer applied to a top surface of the one or more metallic appearance layers.

7. The trim of claim 1, wherein the one or more apertures in the opaque layer are formed by pre-deposition masking or post-deposition laser etching.

8. The trim of claim 2, wherein the one or more apertures in the opaque layer are formed by pre-deposition masking or post-deposition laser etching.

9. The trim of claim 1, wherein at least the one or more metallic appearance layers are applied using a Physical Vapor Deposition (PVD) system.

10. The trim of claim 1, wherein at least the one or more metallic appearance layers are applied using a painting system.

11. The trim of claim 1, wherein the trim is a selectively illuminable trim further comprising a light source disposed below a bottom surface of the substrate, the light source configured to output light through the substrate, the one or more apertures defined by the opaque layer, and the one or more metallic appearance layers.

12. The trim of claim 11, further comprising a light guide disposed between the light source and the bottom surface of the substrate, the light guide configured to distribute light output from the light source.

13. A method of manufacturing a trim piece for an object, the method comprising:

providing a transparent or translucent substrate defining a top surface;

applying an opaque layer over the top surface of the substrate, the opaque layer defining one or more holes through which light can pass; and

one or more semi-transparent metallic look layers are applied over the top surface of the opaque layer.

14. The method of claim 13, further comprising applying a first semi-transparent primer layer to the top surface of the substrate, wherein the opaque layer is applied to a top surface of the first semi-transparent primer layer.

15. The method of claim 14, further comprising applying a second translucent primer layer to portions of the top surface of the first translucent primer layer corresponding to the one or more apertures and the top surface of the opaque layer, wherein the one or more translucent metallic appearance layers are applied to a top surface of the second translucent primer layer.

16. The method of claim 15, further comprising applying a topcoat layer to a top surface of the one or more metallic appearance layers.

17. The method of claim 13, further comprising applying a topcoat layer to a top surface of the one or more metallic appearance layers.

18. The method of claim 14, further comprising applying a topcoat layer to a top surface of the one or more metallic appearance layers.

19. The method of claim 13, further comprising one of: (i) applying a mask to the top surface of the substrate prior to applying the opaque layer, wherein the mask defines the one or more apertures, and (ii) laser etching the opaque layer to form the one or more apertures.

20. The method of claim 14, further comprising one of: (i) applying a mask to the top surface of the first semi-transparent primer layer prior to applying the opaque layer, wherein the mask defines the one or more apertures, and (ii) laser etching the opaque layer to form the one or more apertures.

21. The method of claim 13, wherein at least the one or more metallic appearance layers are applied using a Physical Vapor Deposition (PVD) system.

22. The method of claim 13, wherein at least the one or more metallic appearance layers are applied using a painting system.

23. The method of claim 13, wherein the trim piece is a selectively illuminable trim piece, and the method further comprises disposing a light source below a bottom surface of the substrate, the light source configured to output light through the substrate, the one or more apertures defined by the opaque layer, and the one or more metallic appearance layers.

24. The method of claim 23, further comprising disposing a light guide between the light source and the bottom surface of the substrate, the light guide configured to distribute light output from the light source.

Technical Field

The present application relates generally to decorative trim and, more particularly, to selectively illuminable metallic looking trim and methods of making the same.

Background

Decorative trim is applied to highlight or enhance the visual appearance of the object. For example, vehicle interior and exterior components often have decorative trim. To further enhance the visual appearance of the decorative trim piece, a light source and a light guide may be incorporated into the decorative trim piece to create a light effect. Chrome plating is one example of a decorative trim often utilized for its high gloss appearance. However, chromium deposits can have negative environmental effects, for example, due to the use of hexavalent chromium baths. The chrome plating is also formed from one or more opaque metal layers that do not allow light to pass through and therefore cannot be used in conjunction with backlighting effects. Thus, while such decorative trim pieces work well for their intended purpose, there remains a need for improvement in the related art.

Disclosure of Invention

According to one aspect of the present disclosure, a trim for an object is presented. In one exemplary implementation, the trim piece includes: the display device includes a transparent or translucent substrate defining a top surface, an opaque layer applied over the top surface of the substrate, the opaque layer defining one or more apertures through which light can pass, and one or more translucent metal appearance layers applied over the top surface of the opaque layer.

In some implementations, the decorative article further includes a first translucent primer layer applied to the top surface of the substrate, wherein the opaque layer is applied to the top surface of the first translucent primer layer. In some implementations, the decorative trim further includes a second translucent primer layer applied to the top surface of the opaque layer and to a portion of the top surface of the first translucent primer layer corresponding to the one or more apertures, wherein the one or more translucent metallic appearance layers are applied to the top surface of the second translucent primer layer. In some implementations, the trim piece further includes a topcoat layer applied to a top surface of the one or more metallic appearance layers.

In some implementations, the one or more apertures in the opaque layer are formed by pre-deposition masking or post-deposition laser etching. In some implementations, the one or more apertures in the opaque layer are formed by pre-deposition masking or post-deposition laser etching. In some implementations, at least one or more of the metallic appearance layers are applied using a Physical Vapor Deposition (PVD) system. In some implementations, at least one or more metallic appearance layers are applied using a painting system.

In some implementations, the trim piece is a selectively illuminable trim piece that further includes a light source disposed below the bottom surface of the substrate, the light source configured to output light through the substrate, the one or more apertures defined by the opaque layer, and the one or more metal appearance layers. In some implementations, the trim piece further includes a light guide (light guide) disposed between the light source and the bottom surface of the substrate, the light guide configured to distribute light output from the light source.

According to another aspect of the present disclosure, a method of manufacturing a trim piece for an object is presented. In one exemplary implementation, the method includes: the method includes providing a transparent or translucent substrate defining a top surface, applying an opaque layer over the top surface of the substrate, the opaque layer defining one or more apertures through which light can pass, and applying one or more translucent metal appearance layers over the top surface of the opaque layer.

In some implementations, the method further includes applying a first translucent primer layer to the top surface of the substrate, wherein the opacifying layer is applied to the top surface of the first translucent primer layer. In some implementations, the method further includes applying a second translucent primer layer to the top surface of the opaque layer and portions of the top surface of the first translucent primer layer corresponding to the one or more apertures, wherein the one or more translucent metallic appearance layers are applied to the top surface of the second translucent primer layer. In some implementations, the method further includes applying a topcoat layer to a top surface of the one or more metallic appearance layers.

In some implementations, the method further includes one of: (i) applying a mask to the top surface of the substrate prior to applying the opaque layer, wherein the mask defines one or more apertures, and (ii) laser etching the opaque layer to form the one or more apertures. In some implementations, the method further includes one of: (i) applying a mask to a top surface of the first translucent primer layer prior to applying the opaque layer, wherein the mask defines one or more apertures, and (ii) laser etching the opaque layer to form the one or more apertures. In some implementations, at least one or more metal appearance layers are applied using a PVD system. In some implementations, at least one or more metallic appearance layers are applied using a painting system.

In some implementations, the trim piece is a selectively illuminable trim piece, and the method further includes disposing a light source below a bottom surface of the substrate, the light source configured to output light through the substrate, the one or more apertures defined by the opaque layer, and the one or more metal appearance layers. In some implementations, the method further includes disposing a light guide between the light source and the bottom surface of the substrate, the light guide configured to distribute light output from the light source.

Further areas of applicability of the teachings of the present disclosure will become apparent from the detailed description, claims, and drawings provided hereinafter wherein like reference numerals refer to like features throughout the several views of the drawings. It is to be understood that the detailed description including the disclosed embodiments and the drawings referred to therein are merely exemplary in nature for purposes of illustration only and are not intended to limit the scope of the disclosure, its application, or uses. Thus, variations that do not depart from the gist of the disclosure are intended to be within the scope of the disclosure.

Drawings

FIG. 1 is a cross-sectional view of a defective selectively illuminable decorative item formed via side A masking of a primer layer;

FIGS. 2A-2D are cross-sectional views of different configurations of selectively illuminable trim pieces according to the principles of the present disclosure; and is

FIG. 3 is a flow chart of a method of manufacturing a selectively illuminable trim piece according to the principles of the present disclosure.

Detailed Description

As mentioned above, the chrome plating is formed of one or more opaque metal layers that do not allow light to pass through, which makes it impossible to use it for decorative trim pieces having a backlit effect. The chromium plating also attenuates radar transmission. In addition, B-side masking (i.e., applying an opaque layer to the back surface of the substrate) can cause distortion, particularly when viewed at an angle. Accordingly, an improved selectively illuminable metallic looking trim piece with a-side masking and method of making the same is presented. In other aspects of the disclosure, a metallic looking trim piece comprising a plurality of stacked layers along with a light source and optional light guide is packaged together to form a single integrated module. In some embodiments, these decorative pieces utilize a metallic appearance layer or coating and an opaque backing layer to obtain a metallic appearance component that is aesthetically pleasing as chrome plated. In some embodiments, one or more primer layers are applied. For example, a first primer layer may be applied between the substrate and the opaque layer. An optional second primer layer may also be applied between the opaque layer and the metallic appearance layer. In some embodiments, a topcoat layer is applied on top of the metallic appearance layer.

Referring now to fig. 1, a cross-sectional view of a defective selectively illuminable decorative trim piece 100 formed via a-side masking of a primer layer is shown. Decorative piece 100 includes a stack 104 formed from a plurality of stacked layers. A transparent or translucent substrate 108 forms the bottom of stack 104. Non-limiting examples of substrate 108 include plastics or polymeric materials such as Polycarbonate (PC), Polymethylmethacrylate (PMMA), Acrylonitrile Butadiene Styrene (ABS), styrene acrylics, styrene acrylonitrile polymers, polyamides, and combinations thereof. For vehicle trim applications, the substrate 108 may be an interior component (instrument panel assembly, center console assembly, multimedia or infotainment unit assembly, door trim panel, etc.) or an exterior body component (front or side grille assembly, bumper or fender highlight (accept), headlamp or tail lamp highlight, trunk lid finish, etc.). It should be understood that the systems and methods described herein are not limited to automotive applications and may be applicable to decorative trim pieces for non-automotive applications (electrical and consumer goods, rail, motorcycle, aerospace, etc.).

An opaque layer 112 is applied to the top surface of the substrate 108. Opaque layer 112, although shown as a black primer layer, may have any suitable color or composition to prevent or substantially mitigate light transmission therethrough. Non-limiting examples of opaque layer 112 include epoxy, urethane, and acrylic based curable wet lacquers with opaque color pigments and combinations thereof. The opaque layer 112 defines one or more gaps or holes 116 formed via pre-deposition masking or post-deposition laser etching through which light can pass. The one or more apertures 116 correspond to a designed lighting accent effect, such as, for example, accentuation of an object associated with a trim piece, a logo, a marking, an icon, a theme, a pattern, a button, or other similar accentuation. A translucent primer layer 120 is applied to the top surface of the opaque layer 112 and to the areas on the top surface of the substrate 108 corresponding to the one or more apertures 116. Non-limiting examples of primer layer 120 include transparent or translucent epoxy-based, polyurethane-based, and acrylic-based curable wet lacquers and combinations thereof.

One or more semi-transparent metallic appearance layers 124 are applied (e.g., via physical vapor deposition or PVD) to the top surface of the primer layer 120. It should be understood that as used herein, the term "metallic appearance" refers to an at least partially transparent layer that appears metallic or otherwise provides a "metallic effect. For example, two or more layers may achieve the best aesthetics (primer layer 120+ single metallic appearance layer 124, single primer layer 120+ two metallic appearance layers 124, two metallic appearance layers 124 without primer layer 120, etc.). The metal appearance layer 124 is translucent in that it is formed from a material or coating that includes elements that are translucent (i.e., at least partially light transmissive), such as, but not limited to, transition metals, post-transition metals, metalloids, and combinations thereof (e.g., alloys, such as oxides and oxide alloys). By way of example only, the metallic appearance layer may be a lacquer solution comprising flakes of one or more of the above elements, or a coating formed by PVD or similar techniques via sublimation of one or more of the above elements. It should be understood that a metallic foil or similar material may also be included in primer layer 120 to further enhance the metallic appearance or effect. The thickness of the metal appearance layer 124 should be such that it remains at least translucent when backlit, yet also appears to be metal when not illuminated. The translucency of the metal layer may also be affected by the chemical composition of the reflected layer and the dispersion of the elements.

The metallic appearance layer 124 may also include multiple layers of a single metallic appearance material or different metallic appearance materials applied at different stages to achieve desired optical properties. An optional topcoat layer 128 may be ultimately applied to the top surface of the metallic appearance layer 124. Non-limiting examples of topcoat layers 128 include transparent or translucent epoxy-based, polyurethane-based, and acrylic-based curable wet lacquers and combinations thereof. The optional topcoat layer 128 may serve to both protect the metallic appearance layer 124 (e.g., to prevent chipping, peeling, or scratching) and/or to further enhance the visual aesthetics of the metallic appearance layer 124 (e.g., by enhancing its glossy appearance). It should be understood that the topcoat layer 128 may also include a metallic foil or similar material to further enhance the metallic appearance of the metallic appearance layer 124. It should also be understood that the topcoat layer 128 may also be colored and/or tinted to further enhance this metallic appearance or effect. Non-limiting examples in this regard include blue metallic colors, copper metallic colors, and bronze metallic colors, although any coloring and/or combination of coloring may be utilized.

Decorative piece 100 also includes a light source 132 (e.g., a Light Emitting Diode (LED), an organic LED (oled), an optical fiber, an electroluminescent piece, or similar device, such as a laser light source) and an optional light guide 136 for guiding, focusing, or distributing light generated from light source 132 through substrate 108 and one or more apertures 116 to form a visible field. As shown, defect 140 occurs due to hole 116 formed in opaque layer 112. More specifically, the primer layer or primer layer 120 never forms a flush top surface. The resulting defect 140 appears like a sink mark that propagates through each of the various layers 120, 124, 128. Such defects 140 may be perceived by a human being (e.g., on the top surface of the metallic appearance layer 124 or the topcoat layer 128) by touch and/or by observation. For example, defect 140 may cause visible distortion in the visible field projected by light source 132 and optional light guide 136. Because of this deficiency 140, there remains a need to improve the manufacture of selectively illuminable metallic looking trim pieces.

Referring now to fig. 2A-2D, various configurations of a second embodiment of a selectively illuminable metallic looking trim piece 200 are illustrated. The decorative piece 200 includes a stack 204 formed from a plurality of stacked layers, which may have the same or similar composition as the layers of the stack 104 in fig. 1, described above. In fig. 2A, a first primer layer 212 is applied to the top surface of substrate 208. However, it should be understood that first primer layer 212 may be optional (see, e.g., fig. 2B). An opaque layer 216 is then applied to the top surface of substrate 208 (fig. 2B) or to the top surface of first primer layer 212 (fig. 2A and 2C-2D). The opaque layer 216 defines one or more apertures 220 that may be formed via pre-deposition masking or post-deposition laser etching or another suitable process. Second primer layer 218 may optionally be applied to the top surface of opaque layer 216 and the portion of the top surface of first primer layer 212 corresponding to one or more apertures 220. A metallic appearance layer 224, which may comprise multiple layers applied in sequence, is applied to either the top surface of second primer layer 218 (fig. 2D), or to portions of the top surface of opaque layer 216 and the top surface of substrate 208 (fig. 2B) or the top surface of first primer layer 212 (fig. 2A and 2C) corresponding to one or more apertures 220. A topcoat layer 228 is optionally applied to the top surface of the metallic appearance layer 224. Details regarding the different layer materials and methods of application thereof are discussed below, as well as packaging the stack 204 with the light source 232 and optional light guide 236 to form a single integrated selectively illuminable trim piece module. It should also be understood that the thicknesses of the various layers of stack 204 (and stack 104) are not drawn to scale. In one exemplary implementation, the substrate thickness is about 2 millimeters to 3 millimeters, the primer layer thickness is about 20 microns, and the combined thickness of the opaque layer and the metallic look layer is about 40 nanometers to 150 nanometers.

Referring now to FIG. 3, a flow chart of a method 300 of making the second embodiment of the trim piece 200 of FIGS. 2A-2D is shown. At 304, a transparent or translucent substrate 108 is obtained. The substrate 108 may be formed, for example, using any suitable plastic or polymer processing technique including, but not limited to, injection molding, extrusion, compression molding, thermoforming, and additive manufacturing (e.g., three-dimensional (3D) printing). As previously mentioned, non-limiting examples of the substrate 108 include plastics or polymeric materials such as PC, PMMA, ABS, styrene acrylics, styrene acrylonitrile polymers, polyamides, and combinations thereof. In one exemplary embodiment, the substrate is a plastic interior or exterior body part of a vehicle as previously described herein. At optional 308, a primer layer 112 is applied to the top surface of substrate 108. As previously mentioned, non-limiting examples of primer layer 120 include transparent or translucent epoxy-based, urethane-based, and acrylic-based curable wet lacquers, and combinations thereof. At optional 312, masking is performed. This may include applying a patterned layer that will not allow the opaque layer material to adhere, thereby forming one or more apertures 220. This masking step may be performed, for example, when laser etching is not used.

At 316, the opaque layer 216 is applied. As previously described, the opaque layer 216 may be applied via PVD, Chemical Vapor Deposition (CVD), lacquer application, or another similar technique. At optional 320, laser etching is performed to form one or more apertures 220 in opaque layer 216. This laser etching step may be performed, for example, when masking is not used. At optional 324, second primer layer 218 may be applied to the top surface of opaque layer 216 and portions of the top surface of first primer layer 212 corresponding to one or more apertures 220. Non-limiting examples of the second primer layer 218 include transparent or translucent epoxy-based, polyurethane-based, and acrylic-based curable wet lacquers and combinations thereof. At 328, the metal look layer 224 is applied. In some embodiments, the metallic appearance layer 224 and the one or more primer layers 212, 218 are applied by a PVD system. In one exemplary implementation, the PVD system is a magnetron sputtering system. At optional 332, topcoat layer 228 is applied. As previously mentioned, non-limiting examples of topcoat layers 128 include transparent or translucent epoxy-based, polyurethane-based, and acrylic-based curable wet lacquers and combinations thereof. In some implementations, the topcoat layer 228 is formed such that it has a substantially flush top surface (see, e.g., fig. 2B). Steps 336 and 340 involve packaging the stack 204, light source 232, and optional light guide 236 into a single integrated module.

In addition to eliminating the a-side masking defect shown in fig. 1, the techniques of the present disclosure provide other benefits. These techniques allow better matching of the appearance of non-translucent or opaque PVD applications. This is because conventional translucent PVD stacks are not as bright as non-translucent or opaque PVD stacks. One exemplary non-translucent or opaque PVD stack is a chrome plated trim part such as on a vehicle. Thus, these techniques allow the resulting translucent, metal looking parts to better match such chrome plated parts.

Exemplary embodiments are provided so that this disclosure will be thorough and will fully convey the scope to those skilled in the art. Numerous specific details are set forth, such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that should not be construed to limit the scope of the disclosure. In some exemplary embodiments, well-known procedures, well-known device structures, and well-known technologies are not described in detail.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. The term "and/or" includes any and all combinations of one or more of the associated listed items. The terms "comprises," "comprising," and "having" are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. Unless specifically stated to be performed in a sequential order, the method steps, processes, and operations described herein should not be understood as necessarily requiring their performance in the particular order discussed or illustrated. It is also to be understood that additional or alternative steps may be employed.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as "first," "second," and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

The foregoing description of the embodiments has been presented for purposes of illustration and description. And is not intended to be exhaustive or limiting of the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but are interchangeable if appropriate and can be used in a selected embodiment, even if not specifically shown or described. This can likewise be varied in a number of ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

It will be appreciated that mixtures and matching of features, elements, methods and/or functions between various examples can be expressly contemplated herein so that one of ordinary skill in the art would appreciate from the present teachings that features, elements and/or functions of one example may be incorporated into another example as appropriate, unless described otherwise above.