Selectively illuminable metallic looking trims and their methods of manufacture

A trim for an object and its method of manufacture involve providing a transparent or translucent substrate defining a top surface, applying an opaque layer above 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 metallic-looking layers above a top surface of the opaque layer. In some implementations, the trim is a selectively illuminable trim whereby a light source is arranged beneath a bottom surface of the substrate, the light source being configured to output light through the substrate, the one or more apertures defined by the opaque layer, and the one or more metallic-looking layers.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a 371 U.S. National Stage of International Application No. PCT/EP2019/079206, filed Oct. 25, 2019, which claims priority to Spanish Patent Application No. P201831040, filed Oct. 25, 2018. The disclosures of each of the above applications are incorporated herein by reference in their entirety.

FIELD

The present application generally relates to decorative trims and, more particularly, to selectively illuminable metallic looking trims and their methods of manufacture.

BACKGROUND

Decorative trims are applied to accent or enhance the visual appearance of an object. For example, vehicle interior and exterior components often have decorative trims. To further enhance the visual appearance of a decorative trim, light sources and light guides can be incorporated into the decorative trim to generate a lighting effect. Chrome plating is one example of a decorative trim that is often utilized due to its high gloss appearance. Chrome plating, however, can have a negative environmental impact, e.g., due to the use of hexavalent chromium baths. Chrome plating is also formed of one or more opaque metallic layers that do not allow light to pass through and thus it cannot be used in connection with back-lit lighting effects. Accordingly, while such decorative trims work well for their intended purpose, there remains a need for improvement in the relevant art.

SUMMARY

According to one aspect of the present disclosure, a trim for an object is presented. In one exemplary implementation, the trim comprises a transparent or translucent substrate defining a top surface, an opaque layer applied above the top surface of the substrate, the opaque layer defining one or more apertures through which light can pass, and one or more translucent metallic-looking layers applied above a top surface of the opaque layer.

In some implementations, the trim further comprises a first translucent base coat layer applied to the top surface of the substrate, wherein the opaque layer is applied to a top surface of the first translucent base coat layer. In some implementations, the trim further comprises a second translucent base coat layer applied to the top surface of the opaque layer and a portion of the top surface of the first translucent base coat layer corresponding to the one or more apertures, wherein the one or more translucent metallic-looking layers are applied to a top surface of the second translucent base coat layer. In some implementations, the trim further comprises a top coat layer applied to a top surface of the one or more metallic-looking layers.

In some implementations, the one or more apertures in the opaque layer are formed by pre-deposit masking or post-deposit laser etching. In some implementations, the one or more apertures in the opaque layer are formed by pre-deposit masking or post-deposit laser etching. In some implementations, at least the one or more metallic-looking layers are applied using a physical vapor deposition (PVD) system. In some implementations, at least the one or more metallic-looking layers are applied using a painting system.

In some implementations, the trim is a selectively illuminable trim that further comprises a light source arranged beneath a bottom surface of the substrate, the light source being configured to output light through the substrate, the one or more apertures defined by the opaque layer, and the one or more metallic-looking layers. In some implementations, the trim further comprises a light guide arranged between the light source and the bottom surface of the substrate, the light guide being configured to distribute the light output from the light source.

According to another aspect of the present disclosure, a method of manufacturing a trim for an object is presented. In one exemplary implementation, the method comprises: providing a transparent or translucent substrate defining a top surface, applying an opaque layer above 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 metallic-looking layers above a top surface of the opaque layer.

In some implementations, the method further comprises applying a first translucent base coat layer to the top surface of the substrate, wherein the opaque layer is applied to a top surface of the first translucent base coat layer. In some implementations, the method further comprises applying a second translucent base coat layer to the top surface of the opaque layer and a portion of the top surface of the first translucent base coat layer corresponding to the one or more apertures, wherein the one or more translucent metallic-looking layers are applied to a top surface of the second translucent base coat layer. In some implementations, the method further comprises applying a top coat layer to a top surface of the one or more metallic-looking layers.

In some implementations, the method further comprises 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. In some implementations, the method further comprises one of (i) applying a mask to the top surface of the first translucent base coat 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. In some implementations, at least the one or more metallic-looking layers are applied using a PVD system. In some implementations, at least the one or more metallic-looking layers are applied using a painting system.

In some implementations, the trim is a selectively illuminable trim and the method further comprises arranging a light source beneath a bottom surface of the substrate, the light source being configured to output light through the substrate, the one or more apertures defined by the opaque layer, and the one or more metallic-looking layers. In some implementations, the method further comprises arranging a light guide between the light source and a bottom surface of the substrate, the light guide being configured to distribute the light output from the light source.

DETAILED DESCRIPTION

As discussed above, chrome plating is formed of one or more opaque metallic layers that do not allow light to pass through, which makes it unusable for decorative trim having back-lit lighting effects. Chrome plating also attenuates radar transmission. Additionally, B-side masking (i.e., applying the opaque layer to a back surface of the substrate) can result in distortion, particularly when being viewed at an angle. Accordingly, improved selectively illuminable metallic looking trims having A-side masking and their methods of manufacture are presented. In other aspects of the present disclosure, metallic looking trims comprising multiple stacked layers along with a light source and an optional light guide are packaged together to form single integrated modules. In some embodiments, these trims utilize a metallic-looking layer or coating and an opaque back layer to achieve a metallic looking component that is as aesthetically pleasing as chrome plating. In some embodiments, one or more base coat primer layers are applied. For example, a first base coat primer layer could be applied between the substrate and the opaque layer. An optional second base coat layer could also be applied between the opaque layer and the metallic-looking layer. In some embodiments, a top coat layer is applied atop the metallic looking layer.

Referring now toFIG.1, a cross sectional view of a defective selectively illuminable decorative trim100formed via A-side masking of primer layers is illustrated. The trim100comprises a stack104formed of multiple stacked layers. A transparent or translucent substrate108forms a base of the stack104. Non-limiting examples of the substrate108include plastic or polymer materials, such as polycarbonates (PC), polymethyl methacrylates (PMMA), acrylonitrile butadiene styrenes (ABS), styrene acrylics, styrene acrylonitrile polymers, polyamides, and combinations thereof. For vehicle trim applications, the substrate108could be an interior component (a dash assembly, a center console assembly, a multimedia or infotainment unit assembly, a door trim panel, etc.) or an exterior body component (front or side grille assemblies, bumper or fender accents, head or taillight accents, a trunk lid finisher, etc.). It will be appreciated that the systems and methods described herein are not limited to automotive applications and could be applicable to decorative trims for non-automotive applications (appliances and consumer goods, railway, motorbikes, aerospace, etc.).

An opaque layer112is applied to a top surface of the substrate108. The opaque layer112, while illustrated as a black primer layer, could have any suitable color or composition that prevents or substantially mitigates light transmission therethrough. Non-limiting examples of the opaque layer112comprise epoxy-based, polyurethane-based, and acrylic-based curable wet paints having opaque color pigments and combinations thereof. The opaque layer112defines one or more gaps or apertures116, formed via pre-deposit masking or post-deposit laser etching, through which light is able to pass. The one or more apertures116correspond to a designed lighting accent effect, such as, for example, an accent, logo, indicia, icon, motif, pattern, button, or other similar accent for the object associated with the trim. A translucent base coat primer layer120is applied to a top surface of the opaque layer112as well as to the top surface of the substrate108in areas corresponding to the one or more apertures116. Non-limiting examples of the base coat layer120include epoxy-based, polyurethane-based, and acrylic-based curable wet paints that are transparent or translucent and combinations thereof.

One or more translucent metallic-looking layers124are applied (e.g., via physical vapor deposition, or PVD) to a top surface of the base coat layer120. It will be appreciated that the term “metallic-looking” as used herein refers to an at least partially transparent layer that looks metallic or otherwise provides a “metallic effect.” For example, two or more layers could achieve the optimal aesthetics (base coat layer120+single metallic-looking layer124, single primer layer120+two metallic-looking layers124, two metallic-looking layers124and no primer layer120, etc.). The metallic-looking layer124is translucent because it is formed of a material or coating comprising 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). For example only, the metallic-looking layer could be a paint solution comprising flakes of one or more of the elements described above or a coating formed via sublimiation of one or more of the elements described above via PVD or a similar technique. It will be appreciated that metallic flakes or similar materials could also be included in the primer layer120to further enhance the metallic look or effect. The thickness of the metallic-looking layer124should be such that it remains at least translucent when illuminated by back-lighting while also looking metallic when not illuminated. The translucency of a metallic layer could also be affected by the chemical composition of the layer and dispersion of elements as reflected.

The metallic-looking layer124could also comprise multiple layers of a single metallic-looking material or different metallic-looking materials applied in various stages to achieve the desired optical properties. An optional top coat layer128could be finally applied to a top surface of the metallic-looking layer124. Non-limiting examples of the top coat layer128include epoxy-based, polyurethane-based, and acrylic-based curable wet paints that are transparent or translucent and combinations thereof. The optional top coat layer128could be applied to both protect the metallic-looking layer124(e.g., from chipping, stripping, or scratching) and/or to further enhance the visual aesthetics of the metallic-looking layer124(e.g., by enhancing its glossy appearance). It will be appreciated that the top coat layer128could further include metallic flakes or similar materials to further enhance the metallic-looking of the metallic-looking layer(s)124. It will also be appreciated that the top coat layer128could also be tinted and/or colored to further enhance this metallic look or effect. Non-limiting examples of this include a blue metallic-look, a copper metallic-look, and a bronze metallic-look, but any tinting and/or coloring combinations could be utilized.

The trim100further comprises a light source132(e.g., a light-emitting diode (LED), organic LED (OLED), optical fiber, electroluminescent, or a similar device, such as a laser light source) and an optional light guide136for directing, focusing, or distributing the light generated from the light source132through the substrate108and the one or more apertures116to form a visible field. As shown, a defect140occurs due to the aperture116formed in the opaque layer112. More particularly, the base coat or primer layer120never forms a flush top surface. The resulting defect140appears similar to a sink mark, which propagates through each of the various layers120,124,128. This defect140could be perceivable to a human by touch (e.g., on the top surface of the metallic-looking layer(s)124or the top coat128) and/or by view. For example, the defect140could cause a visible distortion in the visible field projected by the light source132and the optional light guide136. As a result of this defect140, there remains a need for improvement in the manufacture of selectively illuminable metallic-looking trims.

Referring now toFIGS.2A-2D, various configurations of a second embodiment of a selectively illuminable metallic looking trim200are illustrated. The trim200comprises a stack204formed of multiple stacked layers, which can have the same or similar composition as the layers of stack104inFIG.1as described above. InFIG.2A, a first base coat primer layer212is applied to the top surface of a substrate208. It will be appreciated, however, that the first base coat layer212could be optional (see, e.g.,FIG.2B). An opaque layer216is then applied to either the top surface of the substrate208(FIG.2B) or to the top surface of the first base coat layer212(FIGS.2A and2C-2D). The opaque layer216defines one or more apertures220, which could be formed via pre-deposit masking or post-deposit laser etching or another suitable process. A second base coat primer layer218could optionally be applied to a top surface of the opaque layer216and a portion of the top surface of the first base coat layer212corresponding to the one or more apertures220. A metallic-looking layer224, which could comprise multiple layers that are sequentially applied, is applied to either, is applied to either a top surface of the second base coat layer218(FIG.2D) or to the top surface of the opaque layer216and a portion of the top surface of the substrate208(FIG.2B) or a portion of the top surface of the first base coat layer212(FIGS.2A and2C) corresponding to the one or more apertures220. A top coat layer228is optionally applied to a top surface of the metallic-looking layer224. Details regarding the different layer materials and their methods of application, as well as the packaging of the stack204with a light source232and an optional light guide236to form a single integrated selectively illuminable trim module, are discussed below. It will also be appreciated that the thicknesses of the various layers of stack204(and stack104) are not to scale. In one exemplary implementation, the substrate thickness is approximately 2-3 millimeters, the base coat thickness is approximately 20 microns, and the opaque and metallic-looking layer combined thickness is approximately 40-150 nanometers.

Referring now toFIG.3, a flow diagram of a method300of manufacturing the second embodiment of the trim200ofFIGS.2A-2Dis illustrated. At304, the transparent or translucent substrate108is obtained. The substrate108could 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 substrate108include plastic or polymer materials, such as PC, PMMA, ABS, styrene acrylics, styrene acrylonitrile polymers, polyamides, and combinations thereof. In one exemplary implementation, the substrate is a plastic interior component or exterior body component of a vehicle as previously described herein. At optional308, base coat primer layer112is applied to the top surface of the substrate108. As previously mentioned, non-limiting examples of the base coat layer120include epoxy-based, polyurethane-based, and acrylic-based curable wet paints that are transparent or translucent and combinations thereof. At optional312, masking is performed. This could include applying a patterned layer that will not allow the opaque layer material to adhere, thereby forming the one or more apertures220. This masking step could be performed, for example, when laser etching is not being used.

At316, the opaque layer216is applied. As previously discussed, the opaque layer216could be applied via PVD, chemical vapor deposition (CVD), a paint application, or another similar technique. At optional320, laser etching is performed to form the one or more apertures220in the opaque layer216. This laser etching step could be performed, for example, when masking is not being used. At optional324, a second base coat primer layer218could be applied to the top surface of the opaque layer216and a portion of the top surface of the first base coat layer212corresponding to the one or more apertures220. Non-limiting examples of the second base coat layer218include epoxy-based, polyurethane-based, and acrylic-based curable wet paints that are transparent or translucent and combinations thereof. At328, the metallic-looking layer224is applied. In some embodiments, the metallic-looking layer224and the one or more base coat layers212,218are applied by a PVD system. In one exemplary implementation, the PVD system is a magnetron sputtering system. At optional332, the top coat layer228is applied. As previously mentioned, non-limiting examples of the top coat layer128include epoxy-based, polyurethane-based, and acrylic-based curable wet paints that are transparent or translucent and combinations thereof. In some implementations, the top coat layer228is formed such that it has a substantially flush top surface (see, e.g.,FIG.2B). Steps336and340relate to the packaging of the stack204, a light source232, and an optional light guide236into a single integrated module.

The techniques of the present disclosure provide other benefits beyond the elimination of the A-side masking defect illustrated inFIG.1. These techniques allow for better matching to the appearance of non-translucent or opaque PVD applications. This is because a traditional translucent PVD stack is not as bright as a non-translucent or opaque PVD stack. One example non-translucent or opaque PVD stack is a chrome plated trim component, such as on a vehicle. Thus, these techniques allow for better matching of the resulting translucent, metallic-looking components to such chrome plated components.