VEHICLE INTERIOR COMPONENT

Description

TECHNICAL FIELD

The present invention generally relates to components for a vehicle interior and, more particularly, to interior trim parts, for example, vehicle trim panels, having regions of different esthetic characteristics, such as color or material.

Furthermore, the present invention relates to a process for manufacturing such vehicle interior components. BACKGROUND

It is well-known in motor vehicles to provide a trim component, in particular a trim panel, for covering the vehicle interior structure, such as the instrument panel or the door. Such interior trim parts are commonly found on automotive vehicle headliners, door panels, instrument panels, center consoles, as well as various other interior trim components in a vehicle such as an automobile. Typical vehicle interior trim components contain a protective outer skin layer, such as a polyvinylchloride (PVD), and a rigid structural substrate on the back. Quite often, there is also a soft urethane foam interstitial layer disposed between the protective outer skin layer and the rigid structural substrate. A conventional vehicle interior trim part is generally manufactured in a multiple- step process, in which the structural substrate is molded in a first die. The molded structural substrate is then typically adhesively attached to a foam material having an outer trim layer, such as a PVC skin.

It is often desirable to provide such a vehicle trim component, in particular vehicle trim panel, having regions of different esthetic characteristics. For example, it may be desirable to provide a trim panel or instrument panel having regions of different color.

Accordingly, it would be advantageous to provide a vehicle interior component such as a door panel or instrument panel in which different regions of the vehicle interior component have different colors or other esthetic characteristics. There is also a need for ornamented or decorated interior trim parts having a colored and abrasion-resistant coating . Hence, is desired to implement, in a most cost-efficient way, possible unique decorations of interior trim parts in a vehicle interior in order to generate different customer-specific styles. In this context, it is to be mentioned that the so-called In-Mold-Decoration (IMD) process is already known for decorating plastic surfaces. This conventional IM D process is a specific back-molded foil process. In more detail, with the IM D- process, a printed transfer-foil is inserted into an injection mold and then back- injected with a polymer meld. During back-molding, the color of the transfer-foil is at least partly transferred to the casting and is released from the transfer-foil when the injection mold is opened. Thereafter, the coated part can be removed from the injection mold .

With this conventional process, the color originally coated on the transfer-foil is transferred to the casting. Accordingly, for a next process, the transfer-foil needs to be replaced .

One drawback of this kind of decoration, however, is that high quality and, in particular, abrasion-resistant transfer-foils need to be used, which have to match exactly the 2D-geometry of a 3D-body to be decorated. Since the transfer-foil together with the transferable picture has to be replaced at the beginning of each every process, the IM D-process is a relatively cost intensive process for producing refinement. Furthermore, the high consumption of transfer-foils is of disadvantage with respect to environmental compatibility.

Hence, it would also be advantageous to provide a vehicle interior component which can be formed by a more environmentally compatible and cost-effective way, wherein at the same time the vehicle interior component can be refined and, in particular, individually decorated.

Moreover, it would also be advantageous to provide an interior trim component for vehicles, in which - in addition to the primary function of the interior part, namely to cover body elements - more functionalities can be integrated in a particularly simple, inexpensive and environmentally friendly way.

SUMMARY

According to one aspect, the invention is directed to a component for a vehicle interior comprising a base comprising a surface and a depression in the surface, and a first decorative layer coupled to the base and comprising a front surface and a rear surface. The first decorative layer is at least partially contained in the depression of the surface of the base.

According to another aspect, the invention is directed to a component for a vehicle interior formed by a process comprising the steps of:

- providing a mold bottom and a mold top;

heating the mold bottom;

applying ink to the mold bottom;

closing the mold;

injecting resin between the ink and the mold top to provide the component; and

removing the component from at least one of (a) the mold top, (b) the mold bottom.

According to another aspect, the invention is directed to a process for forming a component for a vehicle interior, wherein process comprises at least the steps of:

providing a mold bottom and a mold top;

heating the mold bottom; applying ink to the mold bottom;

closing the mold;

injecting resin between the ink and the mold top to provide the component; and

- removing the component from at least one of (a) the mold top, (b) the mold bottom.

In some embodiments of the component for a vehicle interior, a depth of the depression is less than approximately 50 μιτι as measured in relation to a plane in which the surface of the base is situated . Preferably, a depth of the depression is less than approximately 25 μιτι, and more preferably less than 20 μιτι, as measured in relation to a plane in which the surface of the base is situated .

In some embodiments of the inventive component for a vehicle interior, the component further comprises a mixing area located at least partly between the base and the first decorative layer, said mixing area comprising material of the base and material of the first decorative layer. A depth of the mixing area is preferably less than approximately 10 μιτι and preferably less than 5 μιτι In some embodiments of the inventive component for a vehicle interior, the first decorative layer is at least partially absorbed into the base as the base and the decorative layer are molded into a shape. In this regard, it is conceivable that a mixing area is formed by at least partially absorbing material of the first decorative layer into the material of the base.

According to some embodiments of the inventive component, the base serves as a reinforcement backing of the vehicle interior component. Preferably, the base is at least partly made of an injection molded material and/or a thermoplastic resin material . The base may also at least partly be made of a thermoplastic resin material.

In accordance with some embodiments disclosed herein, the base is at least partly made of a material selected from a group including : polypropylene, polyethylene, acrylonitrile butadiene styrene ("ABS"), polyurethane nylon, any of a variety of homo polymer plastics, copolymer plastics, plastics with special additives, filled plastics, foam material, in particular made of polyurethane, and combinations thereof. Alternatively or in addition, the base may comprise structural fibers. The structural fibers may include natural fibers, in particular hemp, wood, flex, kenaf and/or sisal, and/or synthetic fibers, in particular glass fibers, carbon fibers and/or polymeric fibers.

Alternatively or in addition, the base may comprise a thermoplastic resin. The thermoplastic resin may be selected from a group including : polypropylene (PP), acrylonitrile butadiene styrene (ABS) and/or polycarbonate (PC) binders.

In accordance with some embodiments disclosed herein, the base is constructed from preferably about 50 % natural fibers and preferably about 50 %

polypropylene (PP). According to some embodiments of the present disclosure, the first decorative layer may comprise a printable material, in particular ink. In particular, the first decorative layer may comprise a thermoformable material and/or pigments.

In particular, the first decorative layer may comprise a solvent-based ink, and particularly a one-component ink.

On the other hand, the first decorative layer may also comprise at least one additive selected from a group including : thinner, hardener, cleaner, and/or retarder.

In accordance with some embodiments disclosed herein, the inventive component may further comprise a protective layer, which is configured to cover the surface of the base and the first decorative layer. The protective layer preferably comprises a material different from the material of the base and/or the first decorative layer. More preferably, the protective layer may comprise a printable and/or sprayable material.

For example, the protective layer may comprise a polymer, in particular a polymer of an alkyl ester of acrylic or methacrylic acid . In addition, the protective layer may comprise ethylene. In accordance with some embodiments disclosed herein, the protective layer may have a thickness of less than approximately 100 μιτι, preferably less than approximately 50 μιτι, and more preferably less than approximately 10 μιτι. In some embodiments of the present invention, the protective layer is applied to the complete "A"-surface of the base. Alternatively, the protective layer may also be applied to areas of the "A"-surface of the base only.

According to some embodiments of the present disclosure, the first decorative layer is fully contained in the depression of the base.

Preferably, a depth of the depression may be at least one of (a) substantially equal to a thickness of the first decorative layer, (b) substantially greater than a thickness of the first decorative layer.

In some embodiments disclosed herein, the component may further comprise a protruding area, which is at least partly aligned with the depression of the surface of the base, and which may consist of or which may at least comprise material of the first decorative layer. In this circumstance, it is conceivable that the protruding area has a height of less than approximately 0.5 μιτι, preferably less than approximately 0.3 μιτι, and more preferably around approximately 50 nm to 150 nm, as respectively measured in relation to the plane in which the surface of the base is situated . In accordance with some embodiments disclosed herein, the front surface of the first decorative layer is substantially adjacent to the surface of the base.

In some embodiments of the present invention, the inventive component may further comprise a second decorative layer comprising a first front surface, a second front surface and a rear surface. The second front surface of the second decorative layer may be adjacent the rear surface of the first decorative layer. The second decorative layer may comprise a material different from the material of the base and/or the first decorative layer. The first front surface of the second decorative layer may be substantially adjacent to the front surface of the first decorative layer. Moreover, the first front surface of the second decorative layer may be substantially adjacent to the surface of the base. In accordance with some embodiments disclosed herein, the second decorative layer comprises a polymer, in particular a polymer of an alkyl ester of acrylic or methacrylic acid .

On the other hand, the second decorative layer may have a thickness of less than approximately 150 μιτι, and preferably less than approximately 100 μιτι.

In accordance with some aspects of the inventive process, it is conceivable that the ink is applied to the mold bottom by printing .

According to some embodiments of the inventive process, a protective layer is applied to the mold bottom, preferably by printing or spraying, wherein said protective layer is preferably applied to the mold bottom prior to applying ink to the mold bottom. The protective layer may serve for covering the surface of the base and the first decorative layer of the component.

Moreover, it is conceivable when a further (second) decorative layer is applied at least partly to the ink and/or a mold surface surrounding the ink, preferably after applying ink to the mold bottom.

According to some embodiments disclosed herein, the inventive component is manufactured or formed by a process comprising at least the steps of:

- providing a mold bottom and a mold top;

heating the mold bottom;

applying ink to the mold bottom;

closing the mold;

injecting resin between the ink and the mold top to provide the component; and

removing the component from the mold top and/or the mold bottom.

During this process, the ink applied to the mold bottom is brought into contact with the resin during the process-step of injecting resin between the ink and the mold top. In this way, a strong bonding between the ink on the one hand and the injected resin on the other hand is obtained . In more detail, the adhesion between the ink and the resin is so high that they can be removed from the mold together as a composite. The resin, which is injected between the ink and the mold top to provide the component, may be a thermoplastic meld, i.e., a thermoplastic material which is heated to or above its softening temperature. Such thermoplastic materials provide the appropriate dimensional stability of the component and are adapted to accommodate mechanical forces, which may occur in use.

For applying the ink to the mold bottom, different methods can be used. Since the present invention particularly relates to the refinement and/or decoration of components for a vehicle interior, such as interior trim parts, the ink, which has to be applied to the mold bottom, may contain pigments. The ink is preferably applied to the mold bottom in form of a thin layer having a thickness of less than approximately 100 μιτι, and preferably less than approximately 50 μιτι. In this respect, for the application of the ink to the mold bottom, a spray method or a printing method may be used, by means of which the ink is directly applied to the die surface of the forming tool, i.e. the mold bottom.

In this context, it should be emphasized that the present invention is not limited to a process in which only ink of a single type, in particular color is applied to the mold bottom. Rather, it is particularly preferred if different types of ink are applied (preferably sequentially) to the mold bottom of the molding tool. This may be different colors, but also the application of conductive layers is

conceivable in order to form, e.g . conductors or heating conductors on or in the support material (base).

As stated above, in the inventive process for forming a component for a vehicle interior, after the application of ink to the mold bottom and after closing the mold, resin, e.g . a thermoplastic meld, is injected between the ink and the mold top to provide the component. Then, a strong bonding (adhesion) and/or material bond between the ink and the injected resin is achieved. In order to optimize the adhesion between the ink and the injected resin, in some embodiments of the inventive process, at least locally and prior to injecting resin a bonding agent is applied to the ink previously applied to the mold bottom. In contrast to conventional IM D processes, the invention provides that - during the injection of resin between the ink and the mold top - a preferably complete mass transfer takes place from the mold bottom to the injected resin. In contrast, with the conventional IMD processes, only the color previously applied to a transfer foil is transmitted to plastic parts, while finally the transfer foil remains in the mold. According to some aspects disclosed herein, the invention relates particularly to a process for manufacturing an interior trim component for vehicles, wherein a coating (ink) is applied on at least an area of a negative mold of a forming tool. Thereafter, the applied coating may be brought into contact with a thermoplastic meld, which is injected into the negative mold of the molding tool. In this way, a material bond between the coating and the injected plastic material may be formed by means of accordingly expiring adhesion mechanisms. The adhesion and/or material bond between the coating and the plastic molding is particularly so high that they can be removed from the mold together as a composite. The forming tool may particularly be an injection mold in which the thermoplastic meld may be introduced via an injection molding process.

As used herein, the term "thermoplastic meld" is generally understood to be a thermoplastic material which is heated to or above its softening temperature. The thermoplastic material may provide an appropriate dimensional stability of the interior component and may be adapted to accommodate mechanical forces occurring in use of the component.

In order to apply the at least one coating (material of the first decorative layer) onto the negative mold of the forming tool or in the injection mold, different methods may be used. Since the present invention particularly relates to the refinement and/or decoration of interior trim parts of vehicles, the coating may comprise particularly pigments; said coating is preferably applied in the form of a thin layer on the tool surface. In this respect, for the application of the at least one coating to the tool surface, a spray method or a printing method may be used, by means of which the coating is directly applied to the die surface of the forming tool.

The invention not only offers the advantage that the surface of an interior component can be refined and, in particular, decorated in a particularly easy to implement and cost-effective manner, while at the same time resources can be saved, but also the advantage that a very precise transfer of a print motif on the appropriate surface of the plastic part is possible. This includes intricate printing motifs with very fine microstructures.

In particular, it is also conceivable in this regard to provide the printed image with a grid-like surface structure in order to provide different perceptions in the finished interior component. The different perceptions may depend on the illumination of the trim component. As an example, the perception of gloss and matt contrast between reflective (plan) areas and light-scattering areas is mentioned .

The support material (base) used for the inventive interior trim part is preferably a polycarbonate (PC), in particular, a polycarbonate material marketed by the company Bayer under the name Makrolon®, such as Makrolon® 2805 or

Makrolon® 2807. Although it may be known to use these materials for protective glazing and machine covers, it has been found that such materials also deliver excellent properties when used as a carrier material for vehicle interior parts particularly in combination with the process according to the invention.

Alternatively, it is also conceivable to use as base material for the inventive interior component an amorphous polycarbonate material marketed by the company Albis Plastics under the name ALCOM®, such as ALCOM® PC 740.

Alternatively, it is also conceivable to use as support material (base) for the inventive interior component a polymer blend consisting of polycarbonate (PC) and acrylonitrile-butadiene-styrene copolymer (ABS). Such a polymer blend may combine the advantages of PC and ABS - both materials are known as materials for the housing technology. A blend material sold under the tradename

Bayblend®, such as Bayblend® T65 XF, may be used since this material may provide a particularly good print image transfer.

A solvent-based one-component ink system may be used as the material used for the first decorative layer, including in particular a high-temperature-resistant thermoplastic binder, such as sold by the company Proll under the name

Noriphan® ink, for example, NORIPHAN® HTR.

If, however, the first decorative layer needs to be conductive, an ink is preferably applied with silver nanoparticles, as these inks have the advantage that they require no further binder and that they sinter in a drying step in order to realize in this way specific conductivities. But of course also other inks may be used, for example inks with copper or copper oxide nanoparticles which are chemically reduced in the drying process and also sinter, or inks containing other electrically conductive components, such as graphene, carbon nanotubes, carbon particles, graphite or mixtures thereof.

According to another aspect of the present invention, the at least one coating, which serves as material of the first decorative layer for product finishing or product decoration, is brought into contact with a mold cavity by means of a print pad.

In principle, it is conceivable when a print image is transferred to the mold of the forming tool by using a pad printing technique. The advantage of this print image transmission consists in the elastic deformability of the print pad, which may be made of silicone rubber. Through the deformability of the print pad, it is possible in a particularly easy but yet effective way to print on curved surfaces (convex, concave or irregular) without the risk that the transferred image will be distorted. Due to its elasticity, the print pad may take the shape of the body to be printed (i.e., the tool surface of the forming tool) and may thus transmit the printing motif on the corresponding surface.

Of course, however, other methods for transmitting a print image to be applied to the mold surface are also conceivable, such as ink-jet printing or spraying.

With regard to the inventive interior component, it is conceivable when an additional function is integrated into the interior component by means of the inventive process. This is due to the fact that the inventive process may allow many new possibilities for surface design and simultaneous functional integration.

According to an exemplary implementation of the present invention, it is provided that at least a backlighted area is integrated into the interior component. For this purpose, in some areas, the thickness of a molded and, in particular, injection molded support structure (base) made of a thermoplastic material may be reduced such that a backlight may be realized in this area, in particular by means of an LED light source. Simultaneously, specifically in the area in which the backlight is intended, a corresponding print image may be applied by means of the process according to the present invention.

Additionally or alternatively it is conceivable that, for the integration of a backlighted area into the interior component, the molded and especially injection molded support structure (base) is such partially translucent, especially

transparent, that in this area the realization of a backlight is possible with the help in particular of an LED light source. Again, at the same time a corresponding image may be applied by means of the process according to the invention, in particular selectively in the region in which the backlight is intended.

As a further integration of functions, the application of a conductive coating (especially silver or copper-containing ink) is mentioned, for example in the form of heat conducting paths to selectively heat contact surfaces of the interior component. It is also conceivable to apply a conductive coating to provide electrical contact paths, for example, for an LED light source, which can be integrated as a backlight into the interior part.

The invention is not so limited that only the A-side of the completed interior component is refined, especially decorated, by at least one coating applied to the surface of the forming tool, wherein thermoplastic carrier material heated to or above its softening temperature is subsequently introduced into the molding tool. Rather, it is also conceivable in this connection that a print image is integrated into the opposite surface, i.e., into the B-side, of the finished interior component.

Features of any of the disclosed embodiments may be used in combination with one another without limitation. In addition, other features and advantages of the present disclosure will become apparent to those of ordinary skill in the art through consideration of the following detailed description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the following, the invention will be described by means of several examples. The examples include a number of details of the vehicle interior component and the process for manufacturing such a component, however, not all details shown in the drawings are necessary for defining the invention. Hence, the separate details shown in the drawings can be claimed separately and independently later on. Moreover, the drawings illustrate several embodiments of the invention, wherein identical reference numerals refer to identical or similar elements or features in different views or embodiments shown in the drawings.

FIG. 1A is a perspective view of a vehicle having interior components therein, e.g. vehicle seats, interior trim parts, interior trim components and/or interior accessories, wherein these interior components are at least partly made in accordance with the inventive process.

FIG. I B is a perspective sectional cut view of the vehicle according to

FIG. 1A. FIG. 1C is a perspective view of an instrument panel having various vehicle display options and a vehicle interior component according to an exemplary embodiment of the present invention. FIG. 2A is a perspective sectional cut view of the vehicle interior

component indicated in FIG. 1C.

FIG. 2B is a sectional view through the vehicle interior component of

FIG. 2A taken along the line 2B-2B in FIG. 1C.

FIGS. 3A to 3F are schematic diagrams of a process for manufacturing a

vehicle interior component according to one exemplary embodiment of the present invention. FIGS. 4A to 4G are schematic diagrams of a process for manufacturing a

vehicle interior component according to another exemplary embodiment of the present invention.

FIGS. 5A to 5G are schematic diagrams of a process for manufacturing a

vehicle interior component according to another exemplary embodiment of the present invention. FIGS. 6A to 6F are schematic diagrams of a process for manufacturing a vehicle interior component according to another exemplary embodiment of the present invention. FIGS. 7A to 7D respectively show schematically exemplary embodiments of the component with base (e.g. resin, plastic, injection molded material, etc.) and decorative layer (e.g. ink, deposit, etc.) in partial cross-section. FIGS. 8A and 8B respectively show schematically the effect of operating

conditions of the formation of a component with base and layer.

DETAILED DESCRIPTION

The depicted embodiments are to be understood as illustrative of the invention and not as limiting in any way. It should also be understood that the figures are not necessarily to scale and that the embodiments are sometimes illustrated by graphic symbols, phantom lines, diagrammatic representations and fragmentary views. In certain instances, details which are not necessary for an understanding of the present invention or which render other details difficult to perceive may have been omitted. Before any exemplary embodiments of the invention are described in detail, it is further to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. It is also to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting. For example, the terms "substrate", "base", "ink", and "decorative layer" are intended to be broad terms and not terms of limitation. These components may be used with any of a variety of products or arrangements and are not intended to be limited to use with automotive applications. Moreover, before beginning the detailed description of the exemplary

embodiments, several general comments are warranted about the applicability and the scope of the present invention. According to exemplary embodiments, a vehicle interior component, in particular, a trim component for a vehicle (e.g., a door panel, an instrument panel IP, a trim element of a dash board or a component assembly) is provided that is adapted for use in any variety of application of a vehicle V (e.g ., automobile, plane, train). FIG. 1A is a perspective view of an exemplary vehicle V that may include molded trim parts, trim components and/or interior components.

As illustrated in FIG. I B, the vehicle V includes an interior I having a vehicle seat assembly ST, a floor console FC, and an instrument panel IP. As discussed in detail below, certain components of the seat assembly ST, the door D of the vehicle V, the floor console FC, a center console, the instrument panel IP, and/or other areas within the interior I may include thermoplastic parts, in particular foamed thermoplastic parts. These interior components or trim parts have a class A surface. As used herein, the term "class A surface" means any surface of a vehicle interior trim part or component, that has styling intent, that is either seen, touch or both.

In general, the vehicle interior parts or trim components described in this disclosure may be molded articles having one or more localized or displayed areas, or portions of softness or cushioning. In some embodiments, the molded article may be configured as a trim part or trim panel for use in a vehicle (e.g., automobile, such as car, truck, bus, and the like; airplane; etc.).

The vehicle trim component can be provided with one or more localized discrete areas or portions of softness or cushioning, which enables the trim component to selectively include areas of softness in areas that are likely to be interfaced by a passenger or other individuals, without the need of providing cushioning to the entire trim part. In this manner, the areas of cushioning may be optimized based on the typical passenger experience.

Furthermore, apart from cushioning of the trim component, the optical

characteristics of the trim component, such as color, form, etc., as well as haptic characteristics, can be optimized by choosing different materials such as leather of PVC.

The vehicle interior component described in this disclosure may be employed in a variety of applications, and is generally applicable with any application. As mentioned above, in some embodiments of the present disclosure, the vehicle interior component may be an instrument panel IP, a door panel or any other vehicle interior parts for use in a vehicle V. While the disclosed embodiments may be described as a vehicle trim component, such as an instrument panel IP, the features of the disclosed embodiments are equally applicable with other applications, such as other panels, molded articles and components. The vehicle interior components described herein are molded thermoplastic parts and, in particular foamed thermoplastic parts.

FIG. 1C shows a perspective view of the interior I of the vehicle V of FIG. 1A in greater detail . In more detail, FIG. 1C is a perspective view of an instrument panel IP or dashboard employed in a vehicle, for example, the vehicle V illustrated in FIG. 1A. The instrument panel IP or dashboard illustrated in FIG. 1C has various vehicle display options and trim components according to exemplary embodiments of the present disclosure. As illustrated in FIG. 1C, the interior trim components of the instrument panel IP or dashboard may be provided with at least one decorative layer, for example, in the form of an elongated stripe having a color, form and/or haptic characteristics which is different with regard to the color, form and/or haptic characteristics of the material adjacent to the

decorative layer. The interior I is shown in FIG. 1C to include a door D and an instrument panel IP. The door D and instrument panel IP each may comprise an outer trim component or panel that is formed by a coverstock or cover assembly coupled to a base (e.g ., a rigid base, panel, etc.) for structural support. The trim panel may include a decorative layer coupled to the base to provide a desired appearance

ornamental appearance and/or a functional component. For the purpose of this disclosure, a vehicle interior component coupled to or forming at least partly the instrument panel IP will be further described but should be understood by a person having ordinary skill in the art reading this disclosure that the vehicle interior component could also be coupled to the door D of the vehicle V, or other surfaces within the vehicle V, or used in other applications where a panel with multiple different cover materials is desired (e.g., in applications not involving a vehicle such as vehicle V.

FIG. 2A is a detailed enlargement of a part of the instrument panel IP of FIG. 1C, wherein this part of the instrument panel IP can be regarded as being a vehicle interior component in accordance with one exemplary embodiment of the present disclosure. In FIG. 2A, the vehicle interior component of the instrument panel IP is shown in a perspective sectional cut view. FIG. 2B is a sectional view of the vehicle interior component according to

FIG. 2A, said sectional view being taken along the line 2B-2B in FIG. 1C.

Referring to FIG. 2A, the vehicle interior component 10 according to this exemplary embodiment comprises a base 20 having a surface, which is visible (e.g ., to an occupant) when the vehicle interior component 10 is mounted in a vehicle interior I. In the surface of the base 20, a depression is formed . The interior component 10 according to the exemplary embodiment further comprises a first decorative layer 30 coupled to the base 20 and also comprising a front surface and a rear surface. As illustrated in particular in FIG. 2B, the first decorative layer 30 is at least partly contained in the depression of the surface of the base 20.

According to some embodiments of the present disclosure, the base 20 provides the substantial, if not the entire, structural support for the vehicle interior component 10 generally, and may provide structural support to various

components that are attached to the vehicle interior component 10 (e.g ., arm rest, speakers, handles, etc.)

With the first decorative layer 30, the base 20 further provides an ornamental or decorative appearance. Surfaces of the vehicle interior component 10 that are visible (e.g ., to an occupant), when the vehicle interior component 10 is mounted in a vehicle interior I, are generally referred to as the "A" surface or side. Portions of surfaces of the base 20 may provide an "A" surface. Other portions or surfaces of the base 20 may be obscured or covered by a cover stock, cover assembly, or other components.

According to some exemplary embodiments, the base 20 is a rigid structure and is formed by injection molding a resin, for example a polymer resin, in a process that uses heat and pressure to inject a molten resin into a cavity formed in a mold tool .

According to various exemplary embodiments disclosed herein, the base 20 may be made from a variety from suitable materials. For example, injection molded polypropylene is one material for making the base 20, but other materials can be used, including other thermoplastic resins, such as polyethylene, acrylonitrile butadiene styrene (ABS), polyurethane nylon, any of a variety of homo polymer plastics, copolymer plastics, plastics with special additives, filled plastics, etc. Also, other molding operations may be used to form the base 20, such as injection compression molding, etc.

In some embodiments of the inventive component 10 disclosed herein, the "A" surface of the vehicle interior component 10 may provide an ornamental or decorative appearance to the vehicle interior component 10 using a first decorative layer 30 coupled to the base 20. The first decorative layer may also provide a functional feature to the vehicle interior component 10, a depressed or raised portion of the vehicle interior component 10, a surface different compared to the surface of the base 20, or the like. As schematically indicated in FIG. 2B, a depth of the depression formed in the surface of the base 20 is relatively low compared with the total thickness of the base 20. According to some exemplary embodiments, a depth of the depression is less than approximately 50 μιτι as measured in relation to a plane in which the surface of the base 20 is situated. The base 20 may have a total thickness of approximately 2 mm to approximately 5 mm. In accordance with some embodiments disclosed herein, the base 20 may be provided with a reinforcement layer arranged at least in the area of the

depression on a surface of the base 20 opposite to the depression in which the first decorative layer 20 is at least partly contained in order to provide structural support. The reinforcement layer may be made of the same material as the base 20 and/or may be integrally formed with the base 20.

Although not illustrated in FIG. 2B, the exemplary embodiment of the inventive vehicle interior component 10 may further comprise a mixing area located at least partly between the base 20 and the first decorative layer 30. Such a mixing area may be characterized in that it comprises material of the base 20 on the one hand, and material of the first decorative layer 30 on the other hand.

As will be described in more detail below, the mixing area may be formed by absorbing at least some of the material of the first decorative layer 30 in the material of the base 20.

According to some embodiments disclosed herein, the first decorative layer 30 may comprise a printable material, in particular ink. For example, the first decorative layer 20 may comprise a thermoformable material . Also, the first decorative layer 30 may comprise pigments.

Although not illustrated in FIGS. 2A and 2B, the vehicle interior component 10 may further comprise a protective layer. The term "protective layer" as used herein refers to a layer, which is configured to cover the "A"-surface of the base 20 and the "A"-surface of the first decorative layer 30.

The protective layer may comprise a material different from the material of the base 20 and/or different from the material of the first decorative layer 30. In some embodiments, the protective layer may comprise a printable and/or sprayable material, e.g., a polymer, in particular a polymer of an alkyl ester of acrylic or met acrylic acid. The protective layer may also comprise ethylene.

According to some embodiments of the inventive vehicle interior component 10, the component 10 may comprise at least one further (second) decorative layer not illustrated in FIGS. 2A and 2B. The further (second) decorative layer may comprise a first front surface, a second front surface, and a rear surface, wherein the second front surface of the second decorative layer may be adjacent the rear surface of the first decorative layer. On the other hand, the second front surface of the second decorative layer may be adjacent the front surface of the base, i.e. the surface of the base, in which the depression is formed .

Referring now to FIGS. 3A to 3F, a process for making a vehicle interior component 10 according to an exemplary embodiment may be discussed in greater detail.

Referring to FIG. 3A, in a first process step, a mold comprising a mold bottom MB and a mold top MT is provided . Preferably, the mold bottom M B is then heated to a temperature of between approximately 50 deg. C to approximately 120 deg. C. For this reason, at least the mold bottom M B is provided with corresponding heating means, as

schematically illustrated in FIG. 3A. For the purpose of the present invention, however, it is not mandatory that the mold bottom MB and, in particular, the complete mold bottom MB is heated. Rather, according to some embodiments of the inventive process, the mold bottom MB is not or only locally heated, in particular in areas, in which ink is intended to be applied in a subsequent process step.

As illustrated in FIG. 3B, after heating the mold bottom M B to a desired temperature of approximately 80 deg . C, ink may be applied at a predefined area or at predefined areas to the mold bottom MB. The ink applied to the mold bottom MB serves as material for the first decorative layer 30 in the completed interior component 10.

The ink, i.e., the material of the first decorative layer 30, may be applied to the mold bottom MB by printing . For this purpose, a print pad PP may be utilized as schematically illustrated in FIG. 3B. According to other embodiments disclosed herein, however, the ink, i.e., the material of the first decorative layer 30, may be applied to the mold bottom M B by other techniques, in particular printing techniques or spraying techniques. As schematically illustrated in FIG. 3B, the ink (material of the first decorative layer 30) is applied to the mold bottom M B in such an amount that the ink forms a layer having a thickness, e.g . of approximately 40 μιτι.

Since the ink (the material of the first decorative layer 30) is applied to a heated mold bottom MB, the ink hardly dries up on the mold bottom MB and doesn't blur. This allows a sharp and unblurred borderline between the material of the base 20 and the material of the first decorative layer 30 in the completed vehicle interior component 10. After applying ink to the mold bottom MB, the mold top, i.e. the other half mold, is arranged with regard to the mold bottom MB so that a mold cavity is defined .

In more detail, according to the exemplary embodiment schematically illustrated in FIGS. 3A to 3F, the two mold plates M B, MT are movable relative to each other and define a mold cavity. More particularly and as illustrated in FIG. 3C, in a closed state of the mold, inner surfaces of the mold plates MB, MT and/or the material (ink) of the first decorative layer 30 applied to the mold bottom M B cooperate to collectively define the mold cavity when the mold plates MB, MT are abutted generally along matting surfaces.

As schematically illustrated in FIG. 3C, the so-formed mold cavity is a gap area between the mold bottom M B and the mold top MT. As further schematically illustrated in FIG. 3C, an injection-molding tool is provided in order to inject molten resin into the mold cavity thereby forming the base 20.

In more detail and as schematically illustrated in FIG. 3D, resin, preferably, molten resin is injected between the ink, i.e. the material of the first decorative layer 30 and the mold top MT to provide the component 20.

When injecting resin, the material of the base 20 flows around the ink (material of the first decorative layer 30). During curing of the injected resin, a direct mechanical bonding between the ink and the resin occurs, as schematically illustrated in FIG. 3E. Accordingly, the base 20 comprises a depression in its surface adjacent to the mold bottom, wherein the first decorative layer 30 is at least partly contained in this depression. Finally, the vehicle interior component 10 is demolded after the curing process has been terminated. For this purpose, the mold is opened as illustrated in FIG. 3F.

Referring to FIGS. 4A to 4G, a process for making a vehicle interior component 10 according to another exemplary embodiment will be described in more detail.

According to this exemplary embodiment, a mold assembly comprising a mold bottom MB and a molt top MT is provided . As schematically illustrated in FIG. 4A, at least the mold bottom MB is preferably heated at least partially by means of a heating device schematically illustrated in FIG. 4A.

Thereafter, a material (here: ink) for the first decorative layer 30 is applied to predefined areas of the mold bottom M B. The ink, which serves as material of the first decorative layer 30, may be applied by printing or spraying . In the

embodiment schematically illustrated in FIG. 4B, the ink, i.e., the material of the first decorative layer 30, is applied to dedicated areas of the mold bottom M B by using a print pad PP.

Thereafter, a second decorative layer 32 may be applied to the mold bottom M B and the already applied material (here : ink) of the first decorative layer 30. The material of the second decorative layer 32 may be applied by printing and/or spraying .

As schematically illustrated in FIG. 4C, in the exemplary embodiment, the material of the second decorative layer 32 is applied to the mold bottom M B and also applied to the material (ink) of the first decorative layer 30 by using a print pad PP. The second decorative layer 32 comprises a first front surface, a second front surface, and a rear surface, wherein the second decorative layer 32 is applied to the mold bottom MB and the already applied material of the first decorative layer 30 such that the second front surface of the second decorative layer 32 is adjacent the rear surface of the first decorative layer 30. The surface of the mold bottom may be entirely covered by the material of the first decorative layer and the material of the second decorative layer.

According to the exemplary embodiment schematically illustrated in FIG. 4C, however, only parts of the surface of the mold bottom M B are covered by the material of the first decorative layer 30 and the material of the second decorative layer 32.

After applying the material of the second decorative layer 32, the mold is closed by moving the mold top MT relative to the mold bottom MB such that a mold cavity is formed. In a closed state of the mold (see FIG. 4D) inner surfaces of the mold plates MB, MT and/or the rear surface of the second decorative layer 32 cooperate to collectively define the mold cavity when the mold plates MB, MT are abutted generally along matting surfaces.

As schematically illustrated in FIG. 4D, the so-formed molding cavity may be a corresponding gap area.

As illustrated in FIG. 4E, when resin is injected between the material of the first decorative layer 30, the material of the second decorative layer 32 and the mold top, the resin flows around the material of the first decorative layer 30 and the material of the second decorative layer 32 such as to allow that the material of the second decorative layer is at least partly transferred to the resin, thereby forming a direct mechanical bonding between the material of the second decorative layer 32, the material of the first decorative layer 30, and the resin. This direct mechanical bonding occurs during curing of the resin material as illustrated in FIG. 4F.

Finally, the vehicle trim component 10 is demolded after the curing process has been terminated . For this purpose, the mold is opened as illustrated in FIG. 4G.

Referring to FIGS. 5A to 5G, a process for manufacturing a vehicle interior trim component 10 according to another exemplary embodiment of the present disclosure will be discussed in greater detail .

In more detail, the process schematically illustrated in FIGS. 5A to 5G mostly corresponds to the process schematically illustrated in FIGS. 3A to 3F; however, prior to applying ink to the mold bottom MB (cf. FIG. 5C), a protective layer 40 may be applied to the mold bottom M B as schematically illustrated in FIG. 5B.

In more detail, according to the process schematically illustrated in FIGS. 5A to 5G, the mold bottom MB of the mold is heated . Thereafter, a protective layer may be applied to the complete surface of the mold bottom M B or alternatively to parts of the surface of the mold bottom M B. In the process schematically illustrated in FIG. 5B, the complete "A"-surface of the mold bottom M B is covered by the protective layer 40.

The protective layer 40 may be applied to the mold bottom M B by printing or spraying . Of course, other methods for applying the protective layer 40 are also possible. After applying the protective layer 40 to the mold bottom MB, the material of the first decorative layer 30 (here: ink) is applied preferably to dedicated areas of a rear surface of the already applied protective layer 40.

As schematically illustrated in FIG. 5C, the material of the first decorative layer 30 may be applied to the rear surface of the protective layer 40 by printing, e.g. by means of a corresponding print pad PP.

Thereafter, the mold is closed by moving a mold top relative to the mold bottom such as to form a mold cavity defined by the inner surfaces of the mold plates MB, MT and/or the rear surface of the protective layer 40 and/or the rear and side surfaces of the material of the first decorative layer 30.

When injecting resin into the so-formed mold cavity (cf. FIG. 5E), the resin flows around the material of the first decorative layer 30 thereby providing a direct mechanical bonding between the material of the base 20, the material of the protective layer 40 and the material of the first decorative layer 30. In more detail, a direct mechanical bonding takes place when curing the injective resin, as schematically illustrated in FIG. 5F. After the curing process has been terminated, the vehicle interior component 10 is demolded by removing the component 10 from the mold top MT and/or the mold bottom MB, as schematically illustrated in FIG. 5G. As indicated in FIG. 5G, the protective layer 40 covers the surface of the base 20 and the first decorative layer 30 of the component 10 thereby protecting the respective surfaces of the base 20 and the first decorative layer 30.

Referring now to FIGS. 6A to 6F, a process for manufacturing a vehicle interior component 10 according to another exemplary embodiment of the present disclosure will be discussed in greater detail . In principle, the process schematically illustrated in FIGS. 6A to 6F corresponds to the process schematically illustrated in FIGS. 3A to 3F. Contrary to the process schematically illustrated in FIG. 3A to 3F, however, in the process according to FIGS. 6A to 6F, the mold bottom M B is provided with a protruding area P, which serves for receiving the material of the first decorative layer 30. In this regard, reference is made to FIGS. 6A and 6B.

By providing such a protruding area P in the surface of the mold bottom MB, the first decorative layer 30 is deeper embedded in the base 20 as schematically illustrated in FIG. 6F, thereby providing a further enhanced appearance of the first decorative layer 30 in the completed component 10.

The protruding area P in the surface of the mold bottom MB may have a height of approximately 2 mm, and preferably a height of approximately 1mm. In some embodiments disclosed herein, the ink (, i.e., the material of the first decorative layer 30) is at least partly absorbed into the material of the base 20 (, i.e., injection molded resign) by the process of injection molding .

In more detail, the occurring bonding and adhesion phenomena between the ink 30 and the material of the base 20 (, i.e., injection molded resign) may vary depending form the various parameters. The formation of bonds between a relatively cold ink material, which was inserted or applied onto the surface of the mold cavity before injection molding, and an injected polymer melt may depend particularly from the a temperature of the mold surface and a process timing, i.e., a time-period between applying the ink and injection molding. Providing sufficient bond strength, at least some of the ink material is transferred to the injection molded resin. Possibly influencing factors on the bond strength are a temperature of the mold surface and process timing, i.e., a time-period between applying the ink and injection molding.

For example, in some embodiments disclosed herein, only a very thin (if any) mixing or absorption area may be formed in a region between the ink material of the first decorative layer 30 and the resin material of the base 20. Such a state may be formed by providing a relatively low temperature of the mold

(approximately 40 deg . C), while at the same time a relative long process time between applying the ink and resign injection is selected. This process time may be approximately up to 300 sec.

In other embodiments, however, much more ink material of the first decorative layer 30 may be absorbed into the resin material of the base 20 during resign injection and curing .

For example, a relative broad/thick mixing or absorption area may be formed in a region between the ink material of the first decorative layer 30 and the resin material of the base 20. Such a state may be formed by providing a relatively high temperature of the mold (approximately up to 80 deg . C), while at the same time a relative short process time between applying the ink and resign injection is selected. This process time may be approximately not more than 120 sec.

Referring to FIGS. 7A to 7D the component 10 with base 20 (e.g. resin, plastic, injection molded material, etc.) and decorative layer 30 (e.g. ink, deposit, etc.) is shown schematically in partial cross-section according to exemplary

embodiments.

In FIG. 7A the layer 30 has been deposited (e.g. by pad printing, ink jet printing, nozzle, spray, etc.) in the mold and heated (e.g. warmed, softened, etc.) before molded material for base 20 is injected behind layer 30 in the mold to form the component 10; the mold is then cooled and the component with layer 30 bonded to base 20 is removed or ejected .

In FIG. 7B the component 10 comprises two decorative layers (30, 32) with a second layer 32 deposited over a first layer 30 in the mold with the material for base 20 injected behind second layer 32 in the mold. Component 10 is provided with visible effect produced by adjacent first layer 30 and second layer 32 in base 20 (e.g . adhered, bonded, etc.).

In FIG. 7C a protective layer 40 is deposited (e.g. by pad printing, ink jet printing, sheet, strip, film, etc.) in the mold; then layer 30 is deposited in the mold (e.g . at least partially onto protective layer 40); the mold is heated (e.g . to soften the layers) before molded material for base 20 is injected behind layer 30 in the mold to form the component 10 with layer 30 bonded to base 20 formed with protection layer 40 (e.g . bonded to the surface). In FIG. 7D the layer 30 has been deposited (e.g. by pad printing, ink jet printing, etc.) on a feature (e.g. raised or embossed area, ridge, line, etc.) in the mold; the feature forms a depression (e.g . indentation, recess, etc.) in the component 10 and base 20 for the layer 30 when molded material for base 20 is injected to form the component 10

Referring to FIGS. 8A and 8B the effect of operating conditions of the formation of component 10 with base 20 and layer 30 is indicated schematically.

In FIG. 8A the layer 30 has been deposited (e.g. by pad printing, ink jet printing, etc.) in the mold and heated to a sufficient temperature for softening (e.g.

melting, bonding etc.); molded material for base 20 is injected behind layer 30 in the mold to form the component 10; at the sufficient temperature the material of layer 30 and the material of layer base 20 bond (e.g. adhere, attach, etc.) in a manner that a relatively distinct transition between layer 30 and base 20 is visible in component 10 (e.g . by indicated schematically in cross section)

In FIG. 8B the layer 30 has been deposited (e.g. by pad printing, ink jet printing, etc.) in the mold and heated to a sufficient temperature for absorption (e.g . fusion, diffusion, etc.) with molded material for base 20 injected behind layer 30 in the mold to form the component 10; at the sufficient temperature the material of layer 30 and the material of layer base 20 combine (e.g . fuse, diffuse, merge, melt, absorb, etc.) in a manner that a less distinct transition between layer 30 and base 20 is visible in component 10 (e.g. indicated schematically by in cross section); as indicated schematically the materials may merge or be absorbed in a partial form or gradient (e.g . depending upon material properties and operating conditions). According to exemplary embodiments operating conditions for the system and method would be as used for conventional injection molding of plastics or resins. According to a preferred embodiment operating conditions would be adapted to achieve the intended effect upon layer 30 and base 20 to form component 10. For example, to achieve a bond of layer 30 on base 20 as indicated schematically in FIGS. 7A and 8A, the mold would be heated to approximately 30 to 40 deg C before injection molding of the base (with the material heated to the melting point for the injection molding process, e.g . from 180 deg C to 260 deg C or more as required); before demolding the component the mold would be cooled as in a conventional injection molding process (e.g . cooled to 30 to 40 deg C); see also FIGS. 7B to 7D.

For example, to achieve absorption of layer 30 with base 20 as indicated schematically in FIG. 8B, the mold would be heated to approximately 80 to 100 deg C before injection molding of the base (with the material heated to the melting point for the injection molding process, e.g . from 180 deg C to 260 deg C or more as required); before demolding the component the mold would be cooled as in a conventional injection molding process (e.g . cooled to 30-40 deg C). The steps of heating the mold and depositing (e.g . printing, etc.) the layer maybe reversed according to an alternative embodiment.

According to an exemplary embodiment the base may be formed from

polycarbonate, polypropylene, acrylonitrile butadiene styrene, engineered plastics/resins, etc. ; and the layer may be formed from printing inks made of resin matrix, solvent and pigments, wherein the matrix is formed from acrylic resin, polyurethane resin, polyester resin or mixtures, etc.

According to another exemplary embodiment not illustrated in the drawings, the mold bottom MB may not be provided with a protruding area P, but with a recess for accommodating at least partly the material of the first decorative layer. Such a recess may further increase the sharpness of the first decorative layer 30 in the component 10, because any blurring of the material of the first decorative layer during injection of resin can be effectively avoided .

According to an embodiment of the inventive process for manufacturing a trim component 10, a coating in the form of a printed image is applied to a mold surface. For this purpose a pad printing unit may be used for transferring an ink pattern to a surface of the forming tool .

Subsequently, at least the support structure of the interior trim component 10 is injection molded by injecting plastic in the forming tool, which is preferably an injection forming tool . The viscous melt flows around the color patterns previously applied to the surface of the forming tool . By the inflowing molten plastic material a high adhesion between the color pattern and the material of the plastic melt is produced .

Subsequently the interior trim component 10 is unmolded . The color pattern is then completely embedded in the plastic material.

In accordance with some embodiments, the support structure (= base) of the interior component 10, which has been molded by injection molding, may have a recessed portion, which may serve for forming a backlight. A light source, in particular an LED light source, may be accommodated in the recessed portion in such a manner that light is emitted in the direction of the transferred ink pattern. In this way, a background illuminable area is integrated into the interior component 10 in an easy to implement and efficient manner and without the need for additional processing steps.

In accordance with a further embodiment of the process according to the invention, a color pattern of a coating is introduced in the material of the support structure (base) by means of a plunger serving as molding aid . For this purpose, a color pattern was initially transferred onto the surface of the plunger, preferably by means of a pad printing unit.

Then, the plunger together with the color pattern applied on the surface of the plunger may be driven into a thermoplastic melt. In this way, a material bond between the plastic material and the color pattern may be formed.

After cooling the thermoplastic melt, the interior component 10 together with the embedded color pattern may be removed from the mold .

Although not shown in the drawings, it is of course conceivable that - prior to contact with the thermoplastic melt - an adhesion promoter, etc. is transferred to the applied color pattern in order to increase the adhesion between the color pattern and the plastic molded part.

Moreover, it has proved to be advantageous when the color pattern is transferred to the surface 21 of a heated mold, so that during injection of the thermoplastic melt in the subsequent process step, the color pattern is already partially dried and the contours of the printed image contain less solvent than the interior of the ink layer. In this way, a particularly good adhesion between the injected plastic material and the color can be provided.

Studies have shown that in particular a mold temperature in a range between 60 ° C to 120 ° C, preferably between 80 ° C to 110 ° C, and most preferably about 100 ° C give particularly good ink transfer results, which ensures a particularly accurate reproduction of details.

The invention is not limited to the embodiments schematically illustrated in the drawings, but results from a synopsis of all the features disclosed herein.

In particular, the invention is not so limited that only the A-side of the finished interior trim part is refined and, in particular, decorated by applying at least one coating to the surface of the forming tool, and by subsequently introducing a thermoplastic substrate, which is heated at or above its softening temperature, into the forming tool . In particular, it is conceivable that - in addition or alternatively to the integration of a print image in the A-side of the interior trim part - a print image is integrated into the B-side of the interior trim part. This can be done by providing a base body consisting of a thermoplastic carrier material, which is heated at or above the softening temperature of the thermoplastic material, and then by shaping the heated base body in the forming tool, in particular by driving a plunger into the forming tool, wherein at least one coating has been applied on the surface of the plunger prior to driving the plunger into the forming tool .

The inventive process enables a wide range of products to be produced . In practicing the invention in order to obtain a class A surface on the product the bottom mold and or to mold may be polished. What is claimed as new and desired to be protected is set forth in the appended claims and includes equivalents of the elements recited therein.