Patent ID: 12202401

FIG.1shows a perspective exploded view of an interior trim part according to an example. The interior trim part shown inFIG.1comprises a support layer10, in which various types of perforations12can be formed, whereinFIG.1shows by way of example perforations in the form of circular holes, of a line, of curved shapes and of a triangular shape. The perforations shown inFIG.1serve merely as an example for a multiplicity of possible regular and irregular patterns and structures, images, letterings and the like. The perforations12can be produced in various ways: If the support layer10is an injection molded part, the perforations can be formed e.g. by cutting directly in the injection molding process. Furthermore, the perforations can be produced, irrespective of the type of support layer10, by punching, water jet cutting, laser cutting or also by manually cutting. The support layer10can be produced as an injection molded part from synthetic material or as a pressed fiber-reinforced sheet, to name only two examples.

Onto the front side of the support layer10, in the art referred to as B side, a cover layer14is applied, which can form the visible face of the interior trim part, in the art referred to as A side. The cover layer can be configured so as to be single-layered or multi-layered and is partially transparent or translucent. The cover layer14can comprise at least one of the following layers: a textile, a synthetic foil, for example of PVC, synthetic leather, perforated leather, a spacer layer, a foam layer, a lacquer layer. The cover layer14and the support layer16can be glued to one another.

On the rear side of the support layer10, in the art referred to as C side, one or more identical or different illumination units are arranged. The example ofFIG.1shows four different illumination units, namely an LED strip16, a light conductor18with an LED module20connected thereto, a light-conducting textile22and a housed LED module24. In several embodiments, only one type of light source will be provided, if applicable combined with a light conductor, wherein, however, different illumination units also can be combined. Depending on the shape and size of the perforation and the desired illumination, different types of illumination units and light conductors can be combined, wherein in particular LEDs, OLEDs, laser diodes and electroluminescence (EL) light sources may be considered to be used as light source. For example, optical waveguides formed by injection molding or extruded optical waveguides, rigid and flexible optical waveguides, light-conducting foils and sheets can be combined with the light sources. Light-conducting textiles also can be used, for example woven or knitted textiles of synthetic material optical waveguides (polymeric optical fibers; POF) of PMMA. LEDs can be used as individual LEDs or in the form of LED modules, an LED strip, an LED matrix, an LED array or an LED light box. The illumination unit can emit single-colored or multi-colored light, for example LEDs of different color or RGB LEDs can be used.

The illumination unit can be integrated at least partially into the rear side of the support layer10, by for example individual LEDs of the LED strip16or the LED module24being inserted into the perforation12. The illumination unit can be connected, in addition, with a control device, in order to selectively switch on and off the entire illumination unit or individual illumination components, for example individual LEDs. Here, either the entire illumination unit can be switched on and off and also dimmed, or individual illumination components, for example individual LEDs, can be activated in a sequence, in order to generate a moving light pattern.

FIG.2shows a sectional view through an interior trim part according to an example. InFIG.2the interior trim part is illustrated having the support layer10and the cover layer14. The support layer10includes a perforation12which forms differently shaped openings in the support layer10. In this view, it also can be seen that the cover layer14can consist of several layers, including a foam material layer or spacer layer and a decorative layer, for example a foil, a non-woven material, a woven material, a knitted material, a synthetic leather or a perforated leather. Between the support layer10and the cover layer14in the region of the perforation12an additional light-forming element can be provided, for example a light-forming film, a foil or a strip (not shown). Such an element can for example scatter or bundle the light exiting through the perforation.

FIG.2shows by way of example various illumination units in sectional view, including an LED strip16, a light-conducting textile22and a housed LED module24. In addition, an LED light box26is shown. The illumination units are embedded at least partially into the rear side of the support layer10.

FIGS.3A and3Bshow two interior trim parts according to an example, namely a roof lining30for a motor vehicle having a sunroof or panorama window and a continuous roof lining32, by way of example. InFIGS.3A and3Billuminated perforations of the support layer are indicated by lighter regions. The illuminated perforations can have a decorative character, but also provide an ambient light, a functional light or an orientation light.

FIGS.4A to4Gshow step by step various stages of a method for the production of an interior trim part according to an example. Firstly, as shown inFIG.4A, the support layer10is provided; the rear side of the support layer is designated as C side and the front side is designated as B side. The support layer10can be, for example, a pressed fiber-reinforced sheet of natural and synthetic fibers. As shown inFIG.4B, a perforation12is cut into the support layer10, wherein individual through-holes are formed for example by water jet cutting. As shown inFIG.4C, then a translucent stabilizing layer40can be applied onto the front side or onto the rear side of the support layer10, in order to close the openings of the perforation12and to counteract a weakening of the support layer10owing to the perforation12. The stabilizing layer40is optional and can be provided on the front side of the support layer10, so as not to prevent the integration of the illumination unit on the rear side. It can consist, for example, of a translucent film, a non-woven material, or a knitted material.

Then, as shown inFIG.4D, the cover layer14is applied onto the front side of the support layer10. The cover layer14can, as explained above, comprise a foam layer or spacer layer and a decorative layer. It can be laminated onto the support layer10, if applicable with the use of an adhesive layer.

The production method continues inFIG.4E, wherein the view ofFIG.4Eis rotated through 180° with respect toFIG.4D. InFIG.4E, the illumination unit or a portion of the illumination unit, in the view ofFIG.4Ea light-conducting sheet or foil42, is applied onto the rear side or C side of the support layer10. This illumination unit can, as shown inFIG.4F, be covered by a covering layer44on the rear side of the interior trim part. The covering layer44can prevent light from emerging on the rear side of the trim part; it also can have light-forming properties, for example reflector properties.

FIG.4Gshows a sectional view through a finished interior trim part, which is produced according toFIGS.4A to4F. The light-conducting sheet or foil42can be connected to a light source, for example an LED, in order to form the illumination unit. If individual light-conducting sheets or foils42are provided over different portions of the perforation12, these portions can be illuminated independently of one another.FIG.5shows the interior trim part once again in exploded view. Reference is to be made to the description ofFIGS.4A to4G.

The size and arrangement of the perforation is dependent on the desired optical effects and the desired illumination, but also dependent on the type and thickness of the support layer10. Depending on the type, size and circumference of the perforation, it can be expedient to provide the additional stabilizing layer40. The following values are to be understood as an example: the support layer10can be configured for example from a PU substrate with a thickness of 3-8 mm, or from an injection-molded polymer substrate with a thickness of 2-3.5 mm or from a pressed natural fiber substrate with a thickness of 1.2-3 mm. When the openings of the perforation12have a diameter of approximately 3-8 mm and a maximum length of approximately 500 mm, an additional stabilizing layer40may not be necessary. If, proceeding from the same materials of the support layer10the diameter of the perforation openings lies for example in the range of 5-15 mm, with a length in the order of 1200 mm, the use of a stabilizing layer can be expedient, in order to maintain the structural stability of the support layer. The support layer10, perforation12, cover layer14and if applicable stabilizing layer40can be adapted to one another so that the perforation is not noticeable on the front side of the interior trim part. If a reinforcement of the perforation is to be provided, for example injection-molded components or pressed fiber components, additional glass fiber mats or a translucent strip, which are applied locally, can be provided. A reinforcement of the perforation also can be provided by a metal component, for example a metal ring, or reinforcement integrated into the illumination unit.

FIGS.6A to6Cillustrate an effect which can arise owing to a deformation of the support layer10in the region of the perforation12.FIG.6Bshows the ideal case, in which the structural stability of the support layer10is not impaired by the perforation12. In the case ofFIG.6A, the support layer10is deformed in the region of the perforation12, wherein this deformation is apparent through the cover layer14on the front side of the interior trim part. InFIG.6Can additional reinforcing component46is provided in the region of the perforation12, which counteracts the deformation shown inFIG.6A. In this example, the reinforcing component46can be a synthetic material ring or metal ring or a strip or a foil or the like glued onto the rear side of the support layer10.

FIG.7shows an example of an interior trim part including a flexible light-conducting textile48, for example of light-conducting PMMA fibers, as part of the illumination unit on the rear side of the support layer10.FIGS.8to10show further examples of the illumination unit. The illumination unit ofFIG.8comprises a light conductor50, which is supplied from an LED light source, for example. The light conductor50can extend across several perforation openings12and supply them with light. The illumination unit ofFIG.9comprises a light box52, which in the example which is shown receives light from several LEDs and supplies several perforation openings with light. The light box52can have on its inner side a light-forming layer, for example a reflector layer or a diffusor layer. In the example ofFIG.10, the illumination unit comprises a housed LED56, wherein the perforation opening12on the front side support layer10is covered by an additional light-forming layer58, in this example a diffusor layer. Various light-forming films, strips or foils can be used. For example, a translucent strip can be provided with holographic or nano-lithographic micro-optics, in order to direct or deflect light emitted through the perforation opening, whereby the intensity, form and/or direction of the light can be manipulated. The strip can have a worked surface, in which optically effective shapes are formed, for example in order to shape a round light beam so that it appears as an elliptical, oval or rectangular spot. With such a light-forming strip, for example the light of an irregular light source, for example an LED strip, which produces individual spots of light, can be scattered and/or shaped, for example in order to form a homogeneous straight line of light. In another example, the light can be formed so that it is deflected through the optical strip. The layer58also can be colored.

FIGS.11to13show various examples of the configuration of the perforation12. As shown inFIG.11, it can be configured in the form of straight or bent, curved, intertwined, plaited, intersecting or parallel lines. It can also, as shown inFIGS.12and13, comprise punctiform through-holes which have a circular or polygonal or else irregular footprint. The through-holes can be arranged into a structure relative to one another so that through simultaneous or sequential illumination of several or individual through-holes a graphic pattern, an image or lettering can be represented. This is indicated inFIG.12by the curved line. Of course, different types of perforations also can be combined.

The illumination unit can be actuated by a control unit (not shown). Provision can be made that the light emitted through the individual through-openings of the perforation is switched on and off and/or is varied dynamically. A color change also is possible. For example an “input protocol” featuring a “welcome scenario” is conceivable, in which on opening of the vehicle doors or on starting of the engine, an illumination sequence runs. A coupling with the audio system of the motor vehicle and an actuation of the illumination unit as a function of the operation of the audio system also is conceivable. Furthermore, an actuation of the illumination unit as a function of the vehicle speed or of external occurrences, for example in order to warn the driver of danger, is conceivable. The illuminated interior trim part can provide ambient light for the orientation of the occupants; it can also serve as a reading light or other local illumination.

The illumination unit can be actuated by means of the on-board computer system, also designated as ECU (Electronic Control Unit), of the motor vehicle, but also by means of an external control apparatus, such as a mobile telephone, a tablet or a portable computer.

In addition to generating the optical effects by means of the illuminated perforation, graphic elements also can be provided in the cover layer14, for example in the form of woven-in or printed structures, which can lie in one or more planes. Thereby, it is possible to produce a spatial or respectively three-dimensional impression and hence produce the impression of an extension of space.

The interior trim part can be produced using available tools and production methods, wherein the laminate of support layer10and cover layer14can be bonded and formed in a conventional manner. A structural weakening of the support layer owing to the perforation can be compensated if necessary by an additional stabilizing layer or stabilizing elements. The illumination unit and associated electronics can be arranged on the rear side of the interior trim part and are thereby easily accessible for maintenance and exchange. The illumination of the interior trim part is noticed only when light actually is emitted through the perforation; this function also is designated as “hidden until lit”.