CN117561561A - 用于制造用于车辆的发亮构件的方法 - Google Patents

用于制造用于车辆的发亮构件的方法 Download PDF

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CN117561561A
CN117561561A CN202280045174.2A CN202280045174A CN117561561A CN 117561561 A CN117561561 A CN 117561561A CN 202280045174 A CN202280045174 A CN 202280045174A CN 117561561 A CN117561561 A CN 117561561A
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layer
metal
light
foil
method step
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J·洪佩诺德
P·施密茨
H·塔特科
M·克拉米特
J·帕帕多普洛斯
B-U·基特曼
F·瓦祖拉
U·阿克卡
I·格拉塞尔
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Mercedes Benz Group AG
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Mercedes Benz Group AG
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Abstract

本发明涉及一种用于车辆的发亮构件(1)，具有多层构造，所述多层构造具有集成的电子部件(7，8)以及在可视侧(6)上的外表面，其中，所述层中的一层(5)具有金属，并且其中，在所述具有金属的层(5)的背对所述可视侧(6)的一侧上设有作为电子部件(7，8)的一部分的发光二极管(8)。本发明的特征在于，所述具有金属的层(5)在其面向所述可视侧(6)的表面上局部地被着色层(2)覆盖，其中，所述具有金属的层(5)的未被所述着色层(2)覆盖的部段(3)具有三维构型，在该三维构型的区域内在所述具有金属的层(5)的背对所述可视侧(6)的一侧上设有光解耦结构(9)。

Description

用于制造用于车辆的发亮构件的方法
技术领域
本发明涉及一种用于制造这种发亮构件的方法，以及一种具有这样制造的构件的车辆。
背景技术
到目前为止，车辆领域中的发亮构件，特别是车辆外部覆板中的发亮构件是从现有技术中已知的。例如，个别元件可以从背后被照亮，并且是完全或部分透明的，以便光射出，特别是以特殊的图案射出。由此，例如，在车辆散热器格栅的区域中，可以实现发亮的商标标识等。
这种构件在实践中相对复杂，因为其一方面需要具有所需光学设计的实际构件，另一方面需要分配给该构件的发光单元。尽管有可能使用光导，但该构造从其作为可视侧的表面到其背对该可视侧的表面或背面仍然相对较厚。这是一个相当大的缺点，特别是如果其要用于外部覆板区域中时，因为在许多区域中，由于所需的设计原因，结构空间是非常有限的。
为了解决这个问题，于是可以选择一个非常紧凑的构造。例如，从US 10,485,094B1中已知将发光二极管装入由多个部件组成的二维的注塑结构中。该注塑结构的这种多层构造可以包括在不同材料(包括天然材料、金属等)中的不同的层。根据上述美国专利，，原则上也可以想到，在封闭该构造的外表面、即正面施加金属层，例如铬层。
US2018/0149321 A1描述了多组分注塑工艺的类似构造，在该构造中也装入了发光二极管。在此，中间箔可以包含不同的装饰或颜色。在这种情况下，使用深拉来为发光二极管实现凸起，其然后从可视侧被透明覆盖层覆盖。
WO 2020/168324 A2描述了一种具有发光饰面的车辆装饰部件。在这种情况下，在光导上施加表面并且提供金属封闭层，以便可以经由单个开口射出光。
US2018 014 9321A1描述了由具有用于照明元件的凹槽的多个三维成形的箔层组成的发光结构的实施方式。然后在该发光结构上可以放置从背后被照亮的表面。
US2018/0264991 A1描述了一种光组件，包括车辆的两个尾灯和位于其间的被照亮的装饰条。玻璃罩设有在灯打开时能够被光射穿的半透明铬箔。
此外，从DE 10 2020 005 896 A1中已知一种用于制造车辆的面式的装饰元件的方法。该装饰元件包括可透光的层状体，该层状体具有凹槽或凹陷，该凹槽或凹陷被透明塑料覆盖，因此凹陷在可视侧形成凸起的装饰。该构造可以用光源来照亮。
发明内容
本发明的目的现在是给出一种用于制造发亮构件的改进方法，该方法使得能够简单而有效地实现其他设计方面，特别是在适合用于车辆外部覆板的、节省空间的构件情况下。
根据本发明，该目的通过具有权利要求1中的特征的、特别是具有权利要求1的特征部分中的特征的、用于制造发亮构件的方法来实现。该方法的有利设计方案和改进方案产生于相关的从属权利要求。权利要求6给出了具有以这种方式制造的构件的车辆，并且也实现了该目的。
所要制造的用于车辆的发亮构件包括具有集成的电子部件的多层构造，集成的电子部件尤其包括作为这些电子部件的一部分的发光二极管。其中一个层具有金属并且可以例如形成为金属层或具有金属化层的塑料层。塑料层可以例如用金属气相涂覆/沉积。发亮构件在可视侧上具有外表面，该外表面也称为正面。
现在在具有金属的层上在背对该可视侧的一侧上布置电子部件。在此，具有金属的层在其面向可视侧的表面上局部地或部分地被着色层覆盖，其中，具有金属的层的未被着色层覆盖的部段具有三维构型。即，其从具有金属的层的平面上例如(但不必须地)朝向可视侧变形。在此，具有金属的层本身不必位于一个几何平面内，而是完全可以弯曲，其中，该三维构型高于或低于该层的表面，以达到所需的效果。
在此还提出，在具有金属的层的这些三维成形的部段的区域内在具有金属的层的背对可视侧的一侧或表面上设有光耦出结构。这种光耦出结构可以例如通过印刷或压印被引入到具有金属的层中。其确保来自发光二极管的光通过光耦出结构在着色层中断的区域中耦出，发光二极管从可视侧出发位于具有金属的层的后方，特别是位于在可视侧上部分地覆盖该具有金属的层的着色层的后方。通过这种方式，可以实现横向于各个层的堆叠方向的结构厚度最小的构造，这使得在设计时能够具有非常高的灵活性，因此，例如在合适地施加着色层时对个别部段留空，这些部段一方面允许看到具有金属的层，另一方面在发光二极管接通的情况下从背后被照亮。因此可以非常有效果地呈现例如设计特征、字体、符号等，这尤其可以被用于呈现商标标识、类型名称等。
本发明的用于制造这种发亮构件的方法现在提出了以下阐述的六个基本方法步骤来制造照明构件。在第一方法步骤中，对具有金属的层、特别是铬箔在之后的可视侧上局部地配设着色层，这尤其可以通过印刷，例如通过丝网印刷来实现。然后，在第二方法步骤中，在具有金属的层的背对之后的可视侧的背面上施加一部分的电子部件，例如导体路径等。此外，在该方法步骤中，在具有金属的层的在相对置的正面上不设有着色层的区域中，即在被颜色留空的区域中，实现光耦出结构。所有这些都可以以已知的方式进行，特别是通过丝网印刷，或者在光耦出结构的情况下，通过压印或类似的方式进行。
在下一个方法步骤中，安装不能在一个或多个印刷层上实现的电子部件。这特别适用于发光二极管，而其他电子部件，如电阻、电容等，通常已经可以与导体路径一起也通过在具有金属的层的背面印刷来制造。在该步骤之后，在第四方法步骤中，通过深拉或热成形对未设有着色层的区域进行三维成形，例如，成形为朝着之后的可视侧方向超出于着色层的三维结构。特别是，与例如通过丝网印刷方法印刷光耦出结构相比，在压印光耦出结构时，光耦出结构的加工也可以在该深拉步骤中才进行，特别是如果该深拉步骤是通过适当的工具进行的，该工具在背对之后的可视侧的一侧上向具有金属的层中压印光耦出结构，该具有金属的层尤其可以形成为铬箔。
在另一方法步骤中，然后将承载层施加到具有金属的层的背面，以便一方面稳定目前为止的构造，支撑该三维成形的区域，同时安全地封闭电子部件。例如，如上所述，该步骤可以通过背后注塑或者通过设置另一层箔并在该箔与具有金属的层之间注入用于承载层的材料来进行。
最后，在第六方法步骤中，为可视侧配设作为覆盖层的透明塑料。如上所述，该覆盖层优选地可以是光滑的，因此将至此在可视侧上的三维设计又平整为光滑的表面，在该表面下，三维效果影响下方各层，因此，尽管可以看到三维效果，但不会产生可触觉感知的和/或具有更多污垢积聚的风险的凸起。
如前所述，根据本发明的方法的非常有利的改进方案可以规定，透明覆盖层的施加通过用透明塑料进行浸塑或喷塑、特别是用聚氨酯浸塑来完成。如前所述，根据本发明的方法的非常有利的改进方案，光耦出结构可以在方法步骤2中通过印刷方法，特别是通过丝网印刷方法和/或在方法步骤4中通过压印被引入到具有金属的层中。
根据本发明的方法的非常有利的改进方案，可以规定，具有金属的层形成为铬箔。所谓的铬箔通常是一种塑料箔，其被施加以金属外观，例如通过对其施加以铬、银或类似材料，特别是通过气相涂覆。通过这种方式，可以获得具有相对较小的金属含量的具有金属外观的箔，使得箔至少在一个方向上是可渗光的，并且尤其在另一个方向上反射光。此外，由于金属含量低，该相应的层可以设计成对雷达辐射也在很大程度上是透明的，因此，例如，用于车辆环境传感器的合适的雷达传感器可以放置在发亮构件的后面，而不影响其功能。
根据该方法的另一个非常有利的设计方案，现在可以进一步规定，着色层形成为不透明的着色层。这种不透明的着色层是不透光的，因此，在使用发光二极管照明的情况下，光仅在光耦出结构的区域内耦出，并通过具有金属的层发光，而被着色层覆盖的相邻区域是不透光的。在优选将照明构件用于车辆的外部覆板区域中的情况下，可以规定，着色层具有与车漆相同的颜色，或者具有与设计相匹配的颜色，例如对比色。
本发明的车辆现在包括按照该方法制造的构件。
根据本发明的照明构件的进一步有利设计方案也从实施例中获得，该实施例在下文中参照图更详细地描述。
附图说明
在附图中：
图1示出了可能的发亮构件的原理性前视示意图；并且
图2示出了该发亮构件的一部分的剖面图。
具体实施方式
在图1的图示中，可以看到一个整体被标示为1的发亮构件，其例如可以用于车辆的外部覆板区域中。这例如可以是在传统的内燃机车辆中被称为散热器格栅、在例如电动车辆中不再设计成透气格栅形式而是设计成封闭构件形式的、在车辆前部的部段。构件1本身被局部地设计成车身颜色，并且具有在此以四个矩形和一个圆形状示出的被标示为3的部段，这些部段不被设计成车身颜色，而是在关闭背后照明时呈现金属颜色，例如铬外观。
如图2所示，这些部段被三维地设计，并且在透明的覆盖层4内朝向观看者，从而例如产生众所周知的镀铬商标标识的外观，例如申请人的已知的星形外观。为了实现这一点，该构造现在被如图2的剖面图所示地设计。在此特别注重简单和紧凑的构造，该构造尤其被非常薄地设计，但仍然能够实现三维光学效果。为此，作为中心的组成部分，提供铬箔5作为具有金属的层。铬箔在其面向如图2所示的可视侧6的一侧上设有已经提到的着色层2，该着色层尤其可以是具有车身颜色的着色层。当向铬箔5上部分地施加该着色层2时，对在图1的图示中被标示为3的部段留空。如图2的图示所示，这些部段随后在可视侧6的方向上或原则上还在与可视侧6相反的方向上形成三维结构。
然而，在该第一方法步骤中由铬箔5和部分地施加到该铬箔5上的着色层2制成的组合体首先仍是平的。其然后被配设有至少部分被印刷的电子部件。在此在图2的图示中纯示例性地可以看出被印刷的导体路径7，在其区域中然后安装两个发光二极管8。同样通过印刷，在区域3中同样在铬箔5的背对可视侧6的一侧上施加光耦出结构9，因此该光耦出结构在未被照亮的状态下不能从可视侧6被看到。现在，对由电子部件7、8、铬箔5、着色层2以及在相应部段3中被施加的光耦出结构9组成的组合体进行深拉过程或热成形，以产生图2中已经可见的三维设计。其在部段3内形成了两个从可视侧6可见的小平面(Facetten)。然后，在该三维成形过程之后，安装图2所示的承载层10，例如，通过用该承载层10对该先前构造进行背后注塑。承载层10在此形成为透明或半透明的热塑性塑料。其尤其可以被背后注塑到在具有印刷的导体路径7、发光二极管8和在三维成形的区域3中的光耦出结构9背后的区域中。
最后，该构造用前面提到的覆盖层4密封，该覆盖层4也可以形成为透明热塑性塑料或特别是聚氨酯的浇注层。因此，例如，用该覆盖层4对构件进行喷塑或优选地浸塑，使得覆盖层4的层厚大于部段3的三维构型。因此，在可视侧6上产生一个光滑的表面，在该光滑的表面下，可以相应地看到部段3的三维构型，即这里的小平面结构，但该三维构型不延伸超出于可视侧6的表面。
在不照明的情况下，该构造现在具有由部段3中的铬箔5的铬和在被施加的着色层2中的车身颜色组合而成的光学外观。如果发光二极管8被接通，则通过照亮透明的或半透明的承载层10来产生发亮构件2的背光。然而，着色层2理想地不透光，因此光仅在部段3的区域内由光耦出结构9支持或允许地向可视侧6发射。因此，现在产生的印象是一个带有发亮部段3、例如发亮的商标标识的车身颜色的上漆构件。因此，发光二极管8可以以任何方式实现和操控，因此尤其可以想到不同的颜色、变化的颜色等，以及闪烁，例如依赖于环境亮度的光强度的控制、光强度的增加和减少等等。
因此，整个构件1横向于各个层的堆叠方向被构造得非常紧凑，因此几乎可以毫无问题地集成到任何现有的设计中，并且与具有复杂的、相应的厚的照明技术的现有构造不同，可以简单而有效地集成到现有的设计中，而不必在结构上调整比例和可用的结构空间。

Claims (6)

1.一种用于制造用于车辆的发亮构件(1)的方法，所述发亮构件具有多层构造，所述多层构造具有集成的电子部件(7，8)以及在可视侧(6)上的外表面，其中，所述层中的一层(5)具有金属，并且其中，在所述具有金属的层(5)的背对所述可视侧(6)的一侧上设有作为所述电子部件(7，8)的一部分的发光二极管(8)，其中，所述具有金属的层(5)在其面向所述可视侧(6)的表面上局部地被着色层(2)覆盖，其中，所述具有金属的层(5)的未被所述着色层(2)覆盖的部段(3)具有三维构型，在该三维构型的区域内在所述具有金属的层(5)的背对所述可视侧(6)的一侧上设有光耦出结构(9)，为此，
在第一方法步骤中，为形成所述具有金属的层(5)的箔(5)在面向之后的可视侧(6)的正面上局部地配设着色层(2)；
在第二方法步骤中，为所述箔(5)在背对之后的可视侧(6)的背面上配设至少一部分的电子部件(7，8)，特别是光耦出结构(9)；
在第三方法步骤中，安装包括所述发光二极管(8)在内的其他电子部件(8)；
在第四方法步骤中，通过深拉或热成形对所述箔(5)的未设有所述着色层(2)的部段(3)进行三维成形；
在第五方法步骤中，将承载层(10)施加到所述箔(5)的背面；以及
在第六方法步骤中，为所述箔(5)的可视侧(6)配设作为覆盖层(4)的透明塑料。
2.根据权利要求1所述的方法，
其特征在于，
所述透明覆盖层(4)的施加通过用透明塑料，特别是聚氨酯进行浸塑或喷塑来完成。
3.根据权利要求1或2所述的方法，
其特征在于，
在第二方法步骤中通过印刷和/或在第四方法步骤中通过压印将所述光耦出结构(9)引入到所述箔(5)上/中。
4.根据权利要求1、2或3所述的方法，其特征在于，
使用铬箔(5)作为所述具有金属的层(5)。
5.根据权利要求1至4中任一项所述的方法，
其特征在于，
所述着色层(2)形成为不透明的着色层(2)。
6.一种具有根据权利要求1至5中任一项制造的发亮构件(1)的车辆。
CN202280045174.2A 2021-07-13 2022-06-08 用于制造用于车辆的发亮构件的方法 Pending CN117561561A (zh)

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