CN111065527A

CN111065527A - Metal color decoration capable of selective lighting and manufacturing method thereof

Info

Publication number: CN111065527A
Application number: CN201880038241.1A
Authority: CN
Inventors: 费尔南多·科隆; 塞尔吉奥·皮尔斯; 劳尔·马丁内斯
Original assignee: SRG Global Liria SL
Current assignee: SRG Global Liria SL
Priority date: 2017-06-09
Filing date: 2018-06-08
Publication date: 2020-04-24
Also published as: KR20230125098A; JP2023071725A; EP3600909A1; ES2706652A2; JP2020525326A; ES2693388A1; ES2706652R1; KR20200036842A

Abstract

The metallic object trim piece includes a transparent or translucent substrate defining a top surface and a bottom surface, an opaque layer applied to one of the top surface and the bottom surface of the substrate (the opaque layer defining one or more holes through which light can pass), and one or more semitransparent metallic effect layers applied to the top surface of the opaque layer when the opaque layer is applied to the top surface of the substrate or to the top surface of the substrate when the opaque layer is applied to the bottom surface of the substrate. The one or more metallic effect layers comprise one or more metallic effect paints or one or more layers of digitally printed metallic material. A light source is disposed below a bottom surface of the substrate and generates light that passes through the substrate, the one or more holes, and the one or more metallic effect layers.

Description

Metal color decoration capable of selective lighting and manufacturing method thereof

Cross Reference to Related Applications

The present application is a PCT international application claiming benefit from spanish application No. P201730785 filed on 9.6.2017 and spanish application No. P201830556 filed on 7.6.2018. The disclosures of the above applications are incorporated herein by reference in their entirety.

Technical Field

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

Background

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

Disclosure of Invention

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

In some embodiments, the one or more metallic effect layers comprise one or more metallic effect paint layers. In other embodiments, the one or more metallic effect layers comprise one or more digitally printed metallic effect material layers.

In some embodiments, the one or more metallic effect layers comprise only one or more metallic effect paint color layers. In other embodiments, the one or more metallic effect layers include (i) a translucent primer layer applied to the top surface of the opaque layer and the portion of the substrate corresponding to the one or more apertures and (ii) one or more translucent basecoat layers of metallic effect paint applied to the top surface of the primer layer. In some embodiments, the one or more metallic effect layers further comprise a transparent or translucent topcoat layer applied to the top surface of the one or more basecoat layers, wherein the topcoat layer protects and enhances the metallic effect of the one or more metallic effect layers.

In some embodiments, at least one of the primer layer and the topcoat layer includes metal particles to further enhance the metallic effect of the one or more metallic effect layers. In some embodiments, the topcoat layer is at least one of colored and chromatic to further enhance the metallic effect of the one or more metallic effect layers.

In some embodiments, the trim piece is a selectively illuminable trim piece further comprising a light source disposed below the bottom surface of the substrate, the light source configured to output light through the substrate, the one or more apertures defined by the opaque layer, and the one or more metallic effect layers. In some embodiments, the trim piece further comprises a light guide disposed between the light source and the bottom surface of the substrate, the light guide configured to distribute light output from the light source.

According to another aspect of the present disclosure, a trim for an object is presented. In an exemplary embodiment, the decorative item comprises: a transparent or translucent substrate defining a top surface and a bottom surface, an opaque layer applied to the bottom surface of the substrate, the opaque layer defining one or more apertures through which light can pass,

and one or more semi-transparent metallic effect layers applied to the top surface of the substrate.

In some embodiments, the one or more metallic effect layers comprise only one or more metallic effect paint color layers. In other embodiments, the one or more metallic effect layers comprise (i) a translucent primer layer applied to the top surface of the substrate and (ii) one or more translucent basecoat layers of a metallic effect paint applied to the top surface of the primer layer. In some embodiments, the one or more metallic effect layers further comprise a transparent or translucent topcoat layer applied to the top surface of the one or more basecoat layers, wherein the topcoat layer protects and enhances the metallic effect of the one or more metallic effect layers.

In some embodiments, the trim piece is a selectively illuminable trim piece further comprising a light source disposed below the bottom surface of the substrate, the light source configured to output light through one or more apertures defined by the opaque layer, the substrate, and the one or more metallic effect layers. In some embodiments, the trim piece further comprises a light guide disposed between (i) the light source and (ii) the substrate and the bottom surface of the opaque layer, the light guide configured to distribute light output from the light source.

According to another aspect of the present disclosure, a method of manufacturing a trim piece for an object is presented. In one exemplary embodiment, the method comprises: providing a transparent or translucent substrate defining a top surface and a bottom surface, applying an opaque layer to one of the top surface of the substrate and the bottom surface of the substrate, the opaque layer defining one or more holes through which light can pass, and applying one or more semi-transparent metallic effect layers to one of: (i) a top surface of the opaque layer when the opaque layer is applied to the top surface of the substrate; and (ii) the top surface of the substrate when the opaque layer is applied to the bottom surface of the substrate.

In some embodiments, applying the one or more metallic effect layers comprises applying one or more layers of a metallic effect paint. In other embodiments, applying the one or more metallic effect layers comprises digitally printing the one or more layers of metallic effect material. In some embodiments, the one or more metallic effect layers comprise only one or more metallic effect paint color layers.

In some embodiments, applying the one or more metallic effect layers includes (i) applying a translucent primer layer applied to a top surface of the opaque layer and a portion of the substrate corresponding to the one or more apertures, and (ii) applying one or more translucent color paint layers of a metallic effect paint applied to a top surface of the primer layer. In some embodiments, the method further comprises applying a transparent or translucent topcoat layer to a top surface of the one or more basecoat layers, wherein the topcoat layer protects and enhances the metallic effect of the one or more metallic effect layers.

In some embodiments, applying the opaque layer further comprises: applying an initial opaque layer not defining the one or more apertures, and removing portions of the initial opaque layer corresponding to the one or more apertures and obtaining the opaque layer. In some embodiments, applying the initial opaque layer comprises spraying an opaque primer and curing the sprayed opaque primer to obtain the initial opaque layer, and wherein removing portions of the initial opaque layer comprises laser etching the initial opaque layer.

In some embodiments, applying the opaque layer further comprises: applying a temporary mask layer onto one of the top and bottom surfaces of the substrate, applying an initial opaque layer by spraying an opaque primer onto one of the top and bottom surfaces of the substrate and the temporary mask layer, and removing portions of the temporary mask layer and its associated initial opaque layer to obtain the opaque layer. In other embodiments, applying the opaque layer comprises digitally printing an opaque material to a portion of the top surface of the substrate.

In some embodiments, the method further comprises injection or compression molding, thermoforming, or additive manufacturing the plastic material to form the substrate. In some embodiments, the trim piece is a selectively illuminable trim piece, and the method further comprises: disposing a light source below a bottom surface of the substrate, the light source configured to output light through the substrate, the one or more holes defined by the opaque layer, and the one or more metallic effect layers, and encapsulating the light source and the selectively illuminable trim piece into a single integrated module.

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

In some embodiments, applying the one or more metallic effect layers comprises applying one or more layers of a metallic effect paint. In other embodiments, applying the one or more metallic effect layers comprises digitally printing the one or more layers of metallic effect material.

In some embodiments, the one or more metallic effect layers comprise only one or more metallic effect paint color layers. In other embodiments, applying the one or more metallic effect layers includes (i) applying a translucent primer layer applied to a top surface of the opaque layer and a portion of the substrate corresponding to the one or more apertures, and (ii) applying a translucent color coat layer of one or more metallic effect paints applied to a top surface of the primer layer. In some embodiments, the method further comprises applying a transparent or translucent topcoat layer to a top surface of the one or more basecoat layers, wherein the topcoat layer protects and enhances the metallic effect of the one or more metallic effect layers.

In some embodiments, applying the opaque layer further comprises: applying an initial opaque layer not defining the one or more apertures, and removing portions of the initial opaque layer corresponding to the one or more apertures and obtaining the opaque layer. In some embodiments, applying the initial opaque layer comprises spraying an opaque primer and curing the sprayed opaque primer to obtain the initial opaque layer. In some embodiments, removing portions of the initial opaque layer comprises laser etching the initial opaque layer. In other embodiments, applying the opaque layer further comprises: applying a temporary mask layer to a top surface of the substrate, applying an initial opaque layer by spraying an opaque primer on the substrate and the top surface of the temporary mask layer, and removing the temporary mask layer and its associated portions of the initial opaque layer to obtain the opaque layer. In other embodiments, applying the opaque layer comprises digitally printing an opaque material to a portion of the top surface of the substrate.

In some embodiments, the method further comprises injection or compression molding, thermoforming, or additive manufacturing the plastic material to form the substrate.

In some embodiments, the trim piece is a selectively illuminable trim piece, and the method further comprises disposing a light source below the bottom surface of the substrate, the light source configured to output light through the substrate, the one or more apertures defined by the opaque layer, and the one or more metallic effect layers. In some embodiments, the method further comprises disposing a light guide between the light source and the bottom surface of the substrate, the light guide configured to distribute light output from the light source. In some embodiments, the method further comprises packaging the light source and the selectively illuminable trim piece into a single integrated module.

According to another aspect of the present disclosure, a method of manufacturing a trim piece for an object is presented. In one exemplary embodiment, the method comprises: providing a transparent or translucent substrate defining a top surface and a bottom surface, applying an opaque layer to the bottom surface of the substrate, the opaque layer defining one or more apertures through which light can pass, and applying one or more semi-transparent metallic effect layers to the top surface of the substrate.

In some embodiments, the one or more metallic effect layers comprise only one or more metallic effect paint color layers. In other embodiments, applying the one or more metallic effect layers comprises (i) applying a translucent primer layer, the translucent primer layer applied to the top surface of the substrate, and (ii) applying one or more translucent color paint layers of a metallic effect paint, the translucent color paint layers applied to the top surface of the primer layer. In some embodiments, the method further comprises applying a transparent or translucent topcoat layer to a top surface of the one or more basecoat layers, wherein the topcoat layer protects and enhances the metallic effect of the one or more metallic effect layers.

In some embodiments, applying the opaque layer further comprises: applying an initial opaque layer not defining the one or more apertures, and removing portions of the initial opaque layer corresponding to the one or more apertures and obtaining the opaque layer. In some embodiments, applying the initial opaque layer comprises spraying an opaque primer and curing the sprayed opaque primer to obtain the initial opaque layer. In some embodiments, removing portions of the initial opaque layer comprises laser etching the initial opaque layer. In other embodiments, applying the opaque layer further comprises: applying a temporary mask layer to a bottom surface of the substrate, applying an initial opaque layer by spraying an opaque primer on the substrate and the bottom surface of the temporary mask layer, and removing the temporary mask layer and portions of the initial opaque layer associated therewith to obtain the opaque layer. In other embodiments, applying the opaque layer comprises digitally printing an opaque material to a portion of the top surface of the substrate.

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

Drawings

1A-1B are cross-sectional views of a first embodiment of a selectively illuminable trim piece in accordance with the principles of the present disclosure for two different user perspectives;

FIG. 2 is a flow chart of a method of making a first embodiment of a selectively illuminable trim piece according to the principles of the present disclosure:

FIGS. 3A-3B are cross-sectional views of a second embodiment of a selectively illuminable trim piece in accordance with the principles of the present disclosure for two different user perspectives;

4A-4B are cross-sectional views of alternative first and second embodiments of selectively illuminable trim pieces in accordance with the principles of the present disclosure; and is

FIG. 5 is a flow chart of a method of making a second embodiment of a selectively illuminable trim piece according to the principles of the present disclosure.

Detailed Description

As mentioned above, the chrome plating is formed by one or more opaque metal layers that do not allow light to pass through, which makes it impossible to use it for decorative trim pieces having a backlit effect. The chrome plating also attenuates radar transmissions. Accordingly, an improved selectively illuminable metallic color trim and method of making the same are presented. In other aspects of the disclosure, a metallic color trim comprising a plurality of stacked layers along with a light source and optional light guide is packaged together to form a single integrated module. In some embodiments, these decorative pieces utilize a metallic effect paint and an opaque backing layer to achieve

Such as a chrome-plated aesthetically pleasing metallic colored part. In other embodiments, the decorative pieces utilize digital printing to deposit or apply a metallic effect layer rather than a metallic effect paint. In further embodiments, non-metallic effect paints may be utilized in place of metallic effect paints. For example, a matte finish paint may be utilized. Conventional painting techniques (e.g., rolling, brushing, or spraying) may be used to apply the metallic or non-metallic effect paint. In addition, vacuum deposition or electrostatic (e.g., powder coating) may be used to apply the metallic or non-metallic paint. In each embodiment, a variety of application techniques may be used. The opaque backing layer may be applied, for example, by spraying.

In a first embodiment, an opaque layer is deposited on the top surface of the substrate, thereby positioning the opaque layer closer to the eye of an observing user and producing a sharper image with less distortion, such as when viewed at an angle. In a second embodiment, an opaque layer is deposited on the bottom surface of the substrate, thereby positioning the opaque layer further away from the eye of the viewing user and producing a potentially unsharp image with greater distortion, such as when viewed at an angle. However, the second embodiment is advantageous from a processing point of view, since the opaque layer only needs to have the necessary level of adhesion to the bottom surface of the substrate. These processing advantages may result in reduced costs, which may greatly offset any potential distortion in viewing. In addition, the amount of distortion depends on the thickness of the substrate and the type of light source. Different levels of distortion may be considered acceptable for different applications.

Referring now to fig. 1A-1B, cross-sectional views of a first embodiment of a single integrated module 100 are shown. The module 100 includes a metallic color decorative stack 104 formed from a plurality of stacked layers. A transparent or translucent substrate 108 forms the bottom of the trim piece 104. Details of the formation of the substrate 108 are described in detail below with reference to fig. 2. Non-limiting examples of substrate 108 include plastics or polymeric materials such as Polycarbonate (PC), Polymethylmethacrylate (PMMA), Acrylonitrile Butadiene Styrene (ABS), styrene acrylics, styrene acrylonitrile polymers, polyamides, and combinations thereof. For vehicle trim applications, the substrate 108 may be an interior component (instrument panel assembly, center console assembly, multimedia or infotainment unit assembly, door trim panel, etc.) or an exterior body component (front or side grille assembly, bumper or fender highlight (ace), headlamp or tail lamp highlight (ace), trunk lid trim, etc.). It should be understood that the systems and methods described herein are not limited to automotive applications and may be applicable to decorative trim pieces for non-automotive applications (electrical and consumer goods, rail, motorcycle, aerospace, etc.).

An opaque layer 112 is applied to the top surface of the substrate 108. Details of the application of the opaque layer 112 are described in detail below with reference to fig. 2. Opaque layer 112, although shown as a black primer layer, may have any suitable color or composition to prevent or substantially mitigate light transmission therethrough. Non-limiting examples of opaque layer 112 include epoxy, urethane, and acrylic based curable wet lacquers with opaque color pigments and combinations thereof. The opaque layer 112 may also be digitally printed. The opaque layer 112 defines one or more gaps or apertures 116 through which light can pass. The one or more apertures 116 correspond to a designed lighting accent effect, such as, for example, accentuation of an object associated with a trim piece, a logo, a marking, an icon, a theme, a pattern, a button, or other similar accentuation. A translucent primer layer 120 is optionally applied to the top surface of the opaque layer 112 and to the top surface of the substrate 108 in areas corresponding to the one or more apertures 116. Details of the application of primer layer 120 are described in detail below with reference to fig. 2. Non-limiting examples of primer layer 120 include transparent or translucent epoxy-based, polyurethane-based, and acrylic-based curable wet lacquers and combinations thereof.

One or more semi-transparent metallic effect layers 124 are applied to the top surface of the basecoat layer 120 (or to the opaque layer 112 and portions of the substrate 108 corresponding to the one or more apertures 116 when the primer layer 120 is not applied). For example, two or more paint layers may achieve the best aesthetics (the basecoat layer 120+ a single metallic effect paint layer 124, a single primer layer 120+ two metallic effect paint layers 124, two metallic effect paint layers 124 without the basecoat layer 120, etc.). Alternatively, the metallic effect layer 124 may be applied via digital printing. Details of the application of the metallic effect layer 124 are described in detail below with reference to fig. 2. The metallic effect layer 124 is translucent in that it is formed from a lacquer or printed material that includes translucent (i.e., at least partially light transmissive) elements, 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, the metallic effect paint may be a paint solution comprising flakes of one or more of the above elements. It should be understood that a metallic foil or similar material may also be included in primer layer 120 to further enhance the metallic effect.

The thickness of the metallic effect paint layer 124 should be such that it remains at least translucent when backlit, yet also appears to be metallic when not illuminated. The translucency of the metal layer may also be affected by the chemical composition of the reflected layer and the dispersion of the elements. The metallic effect paint layer 124 may further include multiple layers of a single metallic effect paint or different metallic effect paints applied at different stages to achieve a desired appearance and translucency (i.e., desired optical properties). For example, fig. 4A shows one configuration 400 of the decorative stack 104 that requires only a single metallic effect layer 124 (and no primer layer 120) with one or more layers of colored paint of a metallic effect paint, and an optional topcoat layer 128 for optimal aesthetics, thereby saving cost and reducing complexity. As mentioned above, digital printing may be utilized as an alternative to metallic effect paints. In particular, one or more metallic effect layers may be digitally printed onto the substrate 108, thereby eliminating the need for the primer layer 120.

An optional topcoat layer 128 may be applied to the top surface of the metallic effect layer 124. Details of the application of the optional topcoat layer 128 are described in detail below with reference to fig. 2. Non-limiting examples of topcoat layers 128 include transparent or translucent epoxy-based, polyurethane-based, and acrylic-based curable wet lacquers and combinations thereof. The optional topcoat layer 128 may serve to both protect the metallic effect layer 124 (e.g., to prevent chipping, peeling, or scratching) and/or to further enhance the appearance of the metallic effect layer 124 (e.g., by enhancing its glossy appearance). It should be appreciated that the topcoat layer 128 may include a metallic foil or similar material to further enhance the metallic effect. It should also be appreciated that the topcoat layer 128 may be colored and/or tinted to further enhance the metallic effect. Non-limiting examples of this include the blue metal effect, the copper metal effect, and the bronze metal effect, and any coloring and/or combination of colors may also be utilized.

Although the various

upper layers

112, 120, 124, and 128 are shown as having approximately the same thickness, it should be understood that their actual thicknesses may vary widely and, in most cases, will be substantially less than the thickness of the substrate 108. In one exemplary embodiment, the primer layer 120 may have a thickness of 15 microns, the metallic effect layer 124 may have a thickness of 1 to 3 microns, and the topcoat layer 128 may have a thickness of 20 to 22 microns. This is much thinner compared to standard painting processes, where the primer layer has a thickness of 20 to 25 microns, the pigmented paint layer has a thickness of 12 to 16 microns, and the topcoat layer has a thickness of 30 to 35 microns. In another exemplary embodiment, the primer layer 120 may have a thickness of 3 to 30 micrometers, the metallic effect layer 124 may have a thickness of 1 to 6 micrometers, and the topcoat layer 128 may have a thickness of 10 to 50 micrometers. In this example, the thickness of the metallic effect paint layer 124 still has a much thinner thickness than conventional painting processes.

The single integrated module 100 also includes a light source 132 (e.g., a Light Emitting Diode (LED), organic LED (oled), optical fiber, electroluminescent, or similar device, such as a laser light source) and an optional light guide 136 for directing, focusing, or distributing light generated from the light source 132 through the substrate 108 and one or more apertures 116 to form a visible field 140. Reference 144 denotes the focus or perspective from which the user is observed. As shown in fig. 1A, there is no distortion of the visible field 140 from a direct viewing angle. That is, the perceived width 148 of the viewing user 144 is equal or approximately equal to the actual width of the visible field 140. As shown in fig. 1B, there is minimal distortion of the visible field 140 from an offset or angled perspective. It can be seen that the perceived width 152 of the viewing user 144 is only slightly larger than the actual width of the visible field 140. Thus, the viewing user 144 should still see a clear image as intended when backlit by the light source 132, and the viewing user 144 should see a glossy metallic color layer when not backlit by the light source 132.

Referring now to fig. 2, a flow chart of a method 200 of making a first embodiment of the single integrated module 100 of fig. 1A-1B is shown. At 204, a transparent or translucent substrate is obtained. The substrate 108 may be formed, for example, using any suitable plastic or polymer processing technique including, but not limited to, injection molding, extrusion, compression molding, thermoforming, and additive manufacturing (e.g., three-dimensional (3D) printing). As previously mentioned, non-limiting examples of substrate 108 include plastics or polymeric materials such as PC, PMMA, ABS, styrene acrylics, styrene acrylonitrile polymers, polyamides, and combinations thereof. In one exemplary embodiment, the substrate is a plastic interior or exterior body part of a vehicle as previously described herein.

At 208, opaque layer 112 is applied to the top surface of substrate 108. In one exemplary embodiment, the opaque layer 112 is applied by spraying an opaque primer, which is then cured to form an initial opaque layer. Portions of the initial opaque layer corresponding to the one or more apertures are then removed (e.g., peeled off) to obtain the opaque layer. For example, laser etching may be utilized to remove portions of the initial opaque layer. In another exemplary embodiment, a temporary mask layer is initially applied to the top surface of the substrate 108. The temporary mask layer corresponds to one or more apertures 116 defined by the opaque layer 112. The temporary mask layer may be tape or another adhesive or a rigid masking device. Once the temporary mask layer is applied, an opaque primer is sprayed over the substrate 108 and the temporary mask layer to form an initial opaque layer. The temporary mask layer is then removed, thereby removing portions of the initial opaque layer corresponding to the one or more apertures 116 to obtain the opaque layer 112. As previously mentioned, non-limiting examples of opaque layer 112 include epoxy, urethane, and acrylic based curable wet lacquers with opaque color pigments and combinations thereof. In another exemplary embodiment, the opaque layer 112 is an opaque lacquer deposited using a digital printing process, thereby avoiding the need to use (i) a post laser etching process to define the one or more apertures 116 or (ii) a mask to avoid deposition of the opaque layer 112 and form the one or more apertures 116.

At optional 212, a translucent primer layer 120 is applied to the top surface of the opaque layer 112 and to the substrate 108 in areas corresponding to the one or more apertures 116 defined by the opaque layer 112. Primer layer 120 is applied such that it defines a substantially smooth or flat top surface (e.g., flush) while also having a non-uniform thickness (i.e., thicker in areas corresponding to one or more apertures 116 and thinner in other areas). In one exemplary embodiment, the primer layer 120 is applied by spraying a translucent coating, and then the translucent paint is cured to form the primer layer 120. As previously mentioned, non-limiting examples of primer layer 120 include transparent or translucent epoxy-based, urethane-based, and acrylic-based curable wet lacquers, and combinations thereof.

At 216, a semi-transparent metallic effect layer 124 is applied to the top surface of the topcoat layer 120. The metallic effect layer 124 is applied using any suitable painting or printing process such as, but not limited to, spraying, brushing, rolling, and digital printing, as well as vacuum processes such as Physical Vapor Deposition (PVD) and Chemical Vapor Deposition (CVD) or electrostatic deposition (e.g., powder coating). As previously described, the paint solution includes translucent ((i.e., at least partially light transmissive) elements 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, the metallic effect paint solution may include flakes of one or more of the above-described elements. As previously described, the thickness of the metallic effect paint layer 124 should be such that it remains at least translucent when backlit, but also appears metallic when not illuminated.

At optional 220, an optional transparent or translucent topcoat layer 128 is applied to the top surface of the metallic effect layer 124. In an exemplary embodiment, similar to the primer layer 120, the topcoat layer 128 is applied by spraying a transparent or translucent coating that is then cured to form the topcoat layer 128. As previously mentioned, non-limiting examples of topcoat layers 128 include transparent or translucent epoxy-based, polyurethane-based, and acrylic-based curable wet lacquers and combinations thereof. Potential benefits of providing the topcoat layer 128 include protecting the metallic effect layer 124 from weathering or damage (chipping, scratching, etc.) and/or enhancing the appearance (e.g., gloss) of the metallic effect layer 124. At optional 224, the light source 132 and optional light guide 136 are disposed below a bottom surface of the substrate 108. At optional 228, the trim stack 104 and the light source 132 (and optionally the light guide 136) are assembled or packaged into a single integrated module 100. The method 200 then ends.

Referring now to fig. 3A-3B, cross-sectional views of a second embodiment of a single integrated module 300 are shown. The module 300 includes a metallic color decorative stack 304 formed from a plurality of stacked layers. Decorative stack 304 includes a transparent or translucent substrate 308, substrate 308 having an opaque layer 312 applied to a bottom surface of substrate 308, opaque layer 312 defining one or more apertures 316. Decorative stack 304 also includes an optional translucent primer layer 320, a translucent metallic effect layer 324, and an optional transparent or translucent topcoat layer 328 that is applied sequentially to the top surface of substrate 308. For example, fig. 4B illustrates one configuration 450 of the decorative stack 304 that requires only a single metallic effect layer 324 (and no primer layer 320) and optional topcoat layer 328 for optimal aesthetics, thereby saving cost and reducing complexity. It should be understood that the layers 308-328 may be applied or formed from the same or similar materials and using the same or similar methods as previously described with reference to layers 108-128 of fig. 1A-1B. The same is true for the description relating to the light source 332 and optional light guide 336 and the light source 132 and optional light guide 136.

Although the various

upper layers

312, 320, 324, and 328 are shown as having approximately the same thickness, it should be understood that their actual thicknesses may vary widely, and in most cases will be substantially less than the thickness of the substrate 308. In one exemplary embodiment, the primer layer 320 may have a thickness of 15 microns, the metallic effect layer 324 may have a thickness of 1 to 3 microns, and the topcoat layer 328 may have a thickness of 20 to 22 microns. This is much thinner compared to standard painting processes, where the primer layer has a thickness of 20 to 25 microns, the pigmented paint layer has a thickness of 12 to 16 microns, and the topcoat layer has a thickness of 30 to 35 microns. In another exemplary embodiment, primer layer 320 may have a thickness of 3 to 30 microns, metallic effect layer 324 may have a thickness of 1 to 6 microns, and topcoat layer 328 may have a thickness of 10 to 50 microns. In this example, the thickness of the metallic effect paint layer 324 still has a much thinner thickness than conventional painting processes. As mentioned above, digital printing may be utilized as an alternative to metallic effect paints. In particular, one or more metallic effect layers may be digitally printed onto the substrate 308, thereby eliminating the need for the primer layer 320.

The primary difference between

modules

100 and 300 is that an opaque layer 312 is applied to the bottom surface of substrate 308 in module 300. An optional transparent or translucent bottom coating 318 may also be applied to the bottom surface of substrate 308 in areas corresponding to one or more holes 316 so that the bottom surface (B-side) of decorative stack 304 is flush. Bottom coating 318 may be the same or similar material as optional primer layer 320 and/or optional topcoat layer 328 and may be applied using the same or similar process (e.g., masking). As shown in fig. 3A, the visible field 340 is free of distortion from the direct viewing perspective (see reference 344 representing the viewing user 344). That is, the perceived width 348 of the observing user 344 is equal or approximately equal to the actual width of the visible field 340.

However, as shown in FIG. 3B, there is a significant distortion of the visible field 340 from an offset or angled perspective. It can be seen that the perceived width 352 of the viewing user 344 is substantially greater than the actual width of the visible field 340. Thus, when backlit by the light sources 332, the viewing user 144 will see a less sharp (i.e., slightly distorted) image, while when not backlit by the light sources 332, the viewing user 144 still sees a glossy metallic color layer. However, one benefit of the configuration of the module 300 is easier processing or forming. More specifically, the opaque layer 312 only has to be designed or selected for adhesion to the substrate 308, and not to both the substrate 308 and the primer layer 320 (as required for the opaque layer 112 relative to the substrate 108 and the pigmented paint layer 120 in fig. 1A-1B).

Referring now to fig. 5, a flow chart of a method 500 of manufacturing a second embodiment of a single integrated module 300 is shown. Also, it should be understood that the same or similar processes or methods described above with respect to fig. 1A-1B, 2, and 4A may be utilized to form the module 300 of fig. 3A-3B, 4B, and 500. At 504, a transparent or translucent substrate 308 is obtained. At 508, an opaque layer 312 defining one or more apertures 316 is applied to the back surface of the substrate 308. Although described and illustrated as a second processing step after obtaining substrate 308, it is understood that opaque layer 312 may be applied after application of optional translucent primer layer 320, translucent metallic effect layer 324, and optional transparent or translucent topcoat layer 328, or somewhere between the application of these layers 320-328 but before steps 528 and 532.

At optional 512, primer layer 320 is applied to the top surface of substrate 308. At 516, the metallic effect layer 324 is applied to the top surface of the primer layer 320 using conventional means (e.g., spraying, brushing, rolling, and digital printing) and vacuum processes such as Physical Vapor Deposition (PVD) and Chemical Vapor Deposition (CVD) or electrostatic deposition (e.g., powder coating). At optional 520, a topcoat layer 328 is applied to the top surface of metallic effect layer 324. At optional 524, a light source 332 and an optional light guide 336 are disposed below a bottom surface of the trim stack 304. At optional 428, the trim stack 304 and the light source 332 (and optionally the light guide 336) are assembled or packaged into a single integrated module 300. The method 500 then ends.

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

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

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

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

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

Claims

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

a transparent or translucent substrate defining a top surface;

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

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

2. The trim of claim 1, wherein the one or more metallic effect layers comprise one or more metallic effect paint layers.

3. The trim of claim 1, wherein the one or more metallic effect layers comprise one or more digitally printed metallic effect material layers.

4. The trim of claim 2, wherein the one or more metallic effect layers comprise only one or more layers of colored paint of a metallic effect paint.

5. The trim of claim 2, wherein the one or more metallic effect layers comprise: (i) a translucent primer layer applied to the top surface of the opaque layer and portions of the substrate corresponding to the one or more apertures, and (ii) one or more translucent color paint layers of a metallic effect paint applied to a top surface of the primer layer.

6. The trim of claim 4 or 5, wherein the one or more metallic effect layers further comprise a transparent or translucent topcoat layer applied to a top surface of the one or more basecoat layers, wherein the topcoat layer protects and enhances the metallic effect of the one or more metallic effect layers.

7. The trim of claim 6, wherein at least one of the primer layer and the topcoat layer is at least one of: (i) include metal particles to further enhance the metallic effect of the one or more metallic effect layers, and (ii) be at least one of colored and colored to further enhance the metallic effect of the one or more metallic effect layers.

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

9. The trim of claim 8, further comprising a light guide disposed between the light source and the bottom surface of the substrate, the light guide configured to distribute light output from the light source.

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

a transparent or translucent substrate defining a top surface and a bottom surface;

an opaque layer applied to the bottom surface of the substrate, the opaque layer defining one or more holes through which light can pass; and

one or more semi-transparent metallic effect layers applied to the top surface of the substrate.

11. The trim of claim 10, wherein the one or more metallic effect layers comprise one or more metallic effect paint layers.

12. The trim of claim 10, wherein the one or more metallic effect layers comprise one or more digitally printed metallic effect material layers.

13. The trim of claim 11, wherein the one or more metallic effect layers comprise only one or more layers of colored paint of a metallic effect paint.

14. The trim of claim 13, wherein the one or more metallic effect layers comprise: (i) a translucent primer layer applied to the top surface of the substrate, and (ii) one or more translucent color paint layers of a metallic effect paint applied to the top surface of the primer layer.

15. The trim of claim 13 or 14, wherein the one or more metallic effect layers further comprise a transparent or translucent topcoat layer applied to a top surface of the one or more basecoat layers, wherein the topcoat layer protects and enhances the metallic effect of the one or more metallic effect layers.

16. The trim of claim 15, wherein at least one of the primer layer and the topcoat layer is at least one of: (i) include metal particles to further enhance the metallic effect of the one or more metallic effect layers, and (ii) be at least one of colored and colored to further enhance the metallic effect of the one or more metallic effect layers.

17. The trim of any of claims 10 to 16, wherein the trim is a selectively illuminable trim further comprising a light source disposed below a bottom surface of the substrate, the light source configured to output light through the one or more apertures defined by the opaque layer, the substrate, and the one or more metallic effect layers.

18. The trim of claim 17, further comprising a light guide disposed between (i) the light source and (ii) the bottom surface of the substrate and the opaque layer, the light guide configured to distribute light output from the light source.

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

providing a transparent or translucent substrate defining a top surface and a bottom surface;

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

applying one or more semi-transparent metallic effect layers to one of: (i) a top surface of the opaque layer when the opaque layer is applied to the top surface of the substrate; and (ii) the top surface of the substrate when the opaque layer is applied to the bottom surface of the substrate.

20. The method of claim 19, wherein applying the one or more metallic effect layers comprises applying one or more layers of a metallic effect paint.

21. The method of claim 19, wherein applying the one or more metallic effect layers comprises digitally printing one or more layers of metallic effect material.

22. The method of claim 21, wherein the one or more metallic effect layers comprise only one or more layers of colored paint of a metallic effect paint.

23. The method of claim 22, wherein applying the one or more metallic effect layers comprises: (i) applying a translucent primer layer applied to the top surface of the opaque layer and portions of the substrate corresponding to the one or more apertures, and (ii) applying one or more translucent color paint layers of a metallic effect paint, the one or more translucent color paint layers applied to a top surface of the primer layer.

24. The method of claim 22 or 23, further comprising applying a transparent or translucent topcoat layer to a top surface of the one or more basecoat layers, wherein the topcoat layer protects and enhances the metallic effect of the one or more metallic effect layers.

25. The method of any one of claims 19 to 24, wherein applying the opaque layer further comprises:

applying an initial opaque layer that does not define the one or more apertures; and

removing portions of the initial opaque layer corresponding to the one or more apertures and obtaining the opaque layer.

26. The method of claim 25, wherein applying the initial opaque layer comprises spraying an opaque primer and curing the sprayed opaque primer to obtain the initial opaque layer, and wherein removing portions of the initial opaque layer comprises laser etching the initial opaque layer.

27. The method of any one of claims 19 to 24, wherein applying the opaque layer further comprises:

applying a temporary mask layer to one of said top surface and said bottom surface of said substrate:

applying an initial opaque layer by spraying an opaque primer onto one of the top and bottom surfaces of the substrate and the temporary mask layer; and

removing portions of the temporary mask layer and the initial opaque layer associated therewith to obtain the opaque layer.

28. The method of any one of claims 19 to 24, wherein applying the opaque layer comprises digitally printing an opaque material to portions of the top surface of the substrate.

29. The method of any one of claims 19 to 28, further comprising injection or compression molding, thermoforming or additive manufacturing a plastic material to form the substrate.

30. The method of any of claims 19-29, wherein the trim piece is a selectively illuminable trim piece, and the method further comprises:

disposing a light source below the bottom surface of the substrate, the light source configured to output light through the substrate, the one or more apertures defined by the opaque layer, and the one or more metallic effect layers; and

packaging the light source and the selectively illuminable trim piece into a single integrated module.