DE102014004880A1 - Method for producing a decorative element - Google Patents

Abstract

The inventive method for producing a decorative element provides several layers of natural substances that are bonded together with adhesive and thus forms a composite block of several layers of layers of natural substances. The composite block is then pressed, d. H. The thickness of the composite block is reduced and the layers are firmly joined together. From this composite block, a material disc is separated, wherein the cutting direction is perpendicular to the surface of a layer, that leads along a layered surface of the composite block. Then at least one surface of the material disk, which shows a layer of the material layers, is pickled and ground. The pickling and grinding results in at least a partial sealing of the surface and a viewing angle dependence for the visibility of separating lines formed between the natural material layers by the glue. Depending on the incidence of light and / or viewing angle, different adhesive layers stand out.

Description

Technical area

The present invention relates to decorative elements and their production, as used for example in vehicle as trim in the interior of a vehicle. The decorative element is constructed of layered natural substances, which are subjected to a surface treatment.

State of the art

At least partially made of natural materials decorative elements are for example made DE 10 2010 028 247 and FR 2913028 known.

In FR 2913028 Several layers of leather are stacked and pressed together before a layer of material is peeled out of the resulting block, which is used as decor for example in the interior decoration in the drapery of walls or doors use. The surface of the material layers is untreated.

To DE 10 2010 028 247 For example, a vehicle interior trim is made from a fiber composite material that consists of multiple layered materials of different nature and thickness to realize a variety of surface variations. For example, the materials may be pre-treated for surface design by dyeing before being pressed. DE 10 2010 028 247 further provides the Interieurteil with a transparent liquid-tight layer, which is formed by a film or a liquid-tight coating. For liquid-tight coating is in DE 10 2010 028 247 further stated that this is made of plastic, which is matched to similar plastics, which are embedded in the fiber composite material. For surface treatment, lacquer can also be used. These protective layers continue to aim to seal the surface.

The multitude of surface treatment methods described creates a sealed surface which, while providing a weather-resistant surface, creates a perception of these plastics in terms of feel and appearance.

Description of the invention

The object of the invention is to improve the feel and appearance of previously known decorative elements made of layered natural materials. The object of the invention is achieved by the method having the features of patent claim 1 and the decorative element having the features of claim 14. Advantageous developments of the invention are specified in the subclaims.

The inventive method for producing a decorative element provides several layers of natural substances that are bonded together with adhesive and thus forms a composite block of several layers of layers of natural substances. The layers of natural substances are advantageously pre-pressed, d. H. even before the formation of a composite block reduced in thickness. The composite block is then pressed, d. H. The thickness of the composite block is reduced and the layers are firmly joined together. From this composite block, a material disc is separated, wherein the cutting direction is perpendicular to the surface of a layer, that extends along a layered surface of the composite block. Then at least one surface of the material disk, which shows a layer of the material layers, is pickled and ground.

The pickling and grinding results in at least a partial sealing of the surface and a viewing angle dependence for the visibility of separating lines formed between the natural material layers by the glue. Depending on the incidence of light and / or viewing angle, different adhesive layers stand out. The stain used is advantageously a Farbstoffbeize, d. H. the coloring is produced by admixed powdered or liquid color pigments. Chemical pickling can also be used, with constituents of the materials in natural product and adhesive reacting with the stain and thus changing properties such as structure and color. At the end of the process, there is a natural, porous surface and harmonious color changes from one layer to another. The stain causes a change in hue, but also an emphasis on contrasts between the layers or an adjustment of the shades, depending on the amount and color of the stain used.

When grinding all ablative methods can be used, but the use of abrasive papers is particularly effective, which produce a uniform surface pressure on the material and remove this homogeneous. The grinding is mainly used to adjust the roughness. After pickling, small fibers of the material form, which produce the roughness and are reduced by the grinding.

According to an advantageous embodiment of the invention, the surface between pickling and grinding is ventilated to dry off the surface faster. The grinding may be followed by a surface cleaning to clean the surface of remnants of abraded material.

For the appearance of the surface, it is particularly advantageous to carry out the steps of pickling and grinding in succession, but in several iterations. The stains applied may vary from iteration to iteration and the intensity of application is also varied. Differences in the stain result from the admixture of color pigments. Mainly with red or blue color pigments the color temperature of the stain is set, ie rather reddish warm or bluish cold. Different stains can be applied on top of each other, whereby the uppermost layer has less covering effect than underlying stains.

If the material is ground after the first pickling step, this also has a color-removing effect. With increasing pickling the possibility of sanding the paint out of the material decreases. The maximum number of pickling steps depends on the absorption capacity of the material. If the material is saturated, the stain is no longer absorbed and may dry up as an inhomogeneous adhesive-like stain carpet. The material is completely oversaturated at these points and can no longer be recognized as such. This effect may also be intentional, i. H. It is stained so often, until a relatively smooth and rather greasy shiny, closed surface is created. This effect is favored by the application of shellac and desired. For a near-natural perception, this is not desired, the material application by the pickling is thus rather uniform and thin.

According to an advantageous embodiment of the invention, the pickling and grinding leads to very thin layers that emphasize the porosity of the natural product. Thus, by pickling and grinding layer thicknesses of the visible surface of 100 to 1000 microns, preferably from 100 to 500 microns are desirable. The layer thickness refers to the part of the material, such as natural fiber, which forms a bond with the stain. The stain is low in viscosity, d. H. she moves in and connects to the natural fiber.

The exact thickness of the pickling layer depends on several factors: pre-treatment of the material, frequency of the order, type of order (low = dry, much = wet) and ventilation times between the iterations of the pickling order. The pretreatment by z. B. grinding or roughening determines the capacity of the base material. Basically, highly compressed material is less receptive. According to the invention, a first grinding operation can also be carried out as a pretreatment before the first pickling. Frequent sanding tends to close pores in the material, reducing the absorbency of the material.

By a multiple application, the thickness of the pickling layer increases, as long as a removing process, such as grinding does not counteract. The thickness of the pickling layer is not only defined by the sole thickness of the pickle, because pickling also penetrates into the structure of the natural fiber (is soaked).

For a wet job, d. H. the amount of stain applied exceeds the absorption capacity of the material for a certain period of time, an upper layer which consists only of the stain itself tends to form. Too much application will cause the surface to stick, d. H. The result is islands with an extremely high concentration of stain, which is not absorbed by the material over a longer period of time.

Furthermore, it is advantageous to paint the stained and ground surface. A thin layer of varnish makes it possible to preserve the feel and appearance of the natural substance and make the natural substance perceptible.

In particular natural fibers of hemp, jute, kenaf, sisal, flax, soy, cellulose, wood, paper or a mixture thereof should be used as the natural material, which are light and compressed and also particularly durable. Natural fibers are very open-pored substances, where a particularly balanced treatment by pickling and grinding is important.

The optical effect of the surface can be improved according to a development of the invention in that different adhesive layers have different colors. For example, the first adhesive colorless and another adhesive dark colored, z. B. red, blue, etc., be.

A further visual enhancement is experienced by the surface when, according to a development of the invention, a metal foil is inserted between two layers of natural material and bonded with adhesive. The metal layer thus formed is treated so that it retains its metallic luster even after painting and pickling.

If there are metal lines in the material, they must be removed before applying the stain, eg. B. by masking (also of several metal lines with intervening natural products in common), be protected or subsequently, for. B. by local grinding, be cleaned.

By this subsequent processing of Metallininen the gloss level or the strength of the reflection (Highlight) can be defined. If several metal lines are next to each other, they can be staggered processed and a course of Highlight strength can be set. The strength of the highlights can also be achieved through different material types. The metal layers are advantageously much thinner than the layers of natural material. A suitable material is aluminum, due to the low weight and the degree of hardness. There may also be other, harder materials, eg. As steel, titanium, are used. When cutting but then resulting deformation effects of the softer surrounding layers.

Of course, massive disks can be produced by the method according to the invention, but it is more cost effective when separating the material disc to achieve a layer thickness of 0.5-5 mm, preferably 1-2 mm. A small amount of material is enough to produce a high quality surface.

Advantageous optical effects can be achieved by not treating the entire surface during pickling and / or grinding, but only a non-masked portion. The surface gets so, z. B. perpendicular to the layers, different color gradients, roughness or gloss levels. Before masking, the surface of the material is ground to make the surface more homogeneous and smoother. If this does not happen, the ability of the stain to undermine the masking and to create blurred or fringed edges. The masking is held in place with pressure on the surface to provide this o. G. Counteract effect. An order with a reduced amount of pickling (dry) is advantageous for the accuracy of the contour represented by the masking.

In addition, if the material disc is bent from sticking to a panel, d. H. Curved surfaces (also used as free-form surfaces), improve the possibilities with the perspective of varying reflections and to produce different degrees of gloss of the decorative element. Specifically, the metal lines form a pronounced highlight in the areas of high curvature, especially when bending occurs about an axis that is perpendicular to the orientation of the layers of the natural product.

In addition, other advantages and features of the present invention will become apparent from the following description of preferred embodiments. The features described therein may be implemented alone or in combination with one or more of the above-mentioned features insofar as the features are not contradictory. The following description of the preferred embodiments will be made with reference to the accompanying drawings.

Short description of the figures

1 shows a composite block,

2 shows the separation of a material disc from the composite block,

3 shows the surface of a material disc in plan view,

4 shows a schematic representation of a material disk in side view,

5 shows a schematic representation of a material disk after painting in side view,

6 shows a schematic representation of a material disk with masked surface treatment in side view,

7 shows a decorative element according to the invention,

8th shows the procedure of the method according to the invention.

A composite block 10 to 1 consists of several layers of natural material, formed here from natural fiber 11 , The natural fiber 11 consists of z. As kenaf, hemp, flax or sisal - and combinations with each other - with a transparent plastic matrix. Alternatively, a colored, eg black plastic matrik may be used which may be partially bleached with a chemical stain. For example, there are seven layers of natural fiber 11 illustrated, it can be made according to the invention, however, composite blocks with a much larger number of layers. Between the layers of natural fiber 11 are layers of glue 12 . 13 arranged, which bring about a connection of the layers with each other. Some of these glue layers 12 consist of a transparent adhesive, other layers 13 from a dark colored glue. In addition, two layers of aluminum foil 17 , which are much thinner than the natural fiber layers 11 represented. This aluminum foil 17 is similar to the glue between the layers of natural fiber 11 arranged and also connected by means of adhesive with the above and below layers. The dimensions of the layers (except the thickness) of natural fiber 11 , Aluminum foil 17 and glue 12 . 13 is essentially the same, so that in the further processing steps on the composite block 10 as little waste as possible. The illustrated composite block 10 is already pressed, ie the thickness of the layers, in particular, reduces the thickness of the natural fiber layer 11 under the influence of the pressing pressure, has the dimensions required for later use.

To 2 is at the aforementioned composite block 10 a section parallel to a surface of the composite block 10 executed and thus a material disc 14 from the composite block 10 separated out. The cutting direction R parallel to the surface is based on the perpendicular to the material layers, so that the material disc 14 consists of a layered composite of natural fiber, aluminum foil and adhesive. The separation of the material disc 14 takes place with a knife on the firmly clamped composite block 10 , so also very thin material discs 14 can arise. The thickness of the material disc is 1 mm, leaving the composite block 10 Overall, a large number of decorative elements can be produced.

In 3 is the material disc 14 in plan view of the visible on later use as a decorative element layered surface 15 shown. This surface 15 has due to the different materials used a rough and possibly irregular expression, will be worked on in the further processing steps.

This roughness is on both layered surfaces of the material disc 14 , to 4 is shown in a side view that only one of the surfaces 15 while the back surface remains untreated and rough. The surface 15 is sanded first, cleaned of sanding residue and then with a mordanting layer 16 Mistake. The stain contains color pigments, for example dark brown, which adjust a wood color. Alternatively, the stain may also contain foreign substances, such as metal, glass, diamond or stone particles, which refine the surface accordingly.

The stain partially penetrates into the structures of the natural fiber and the adhesive, partially remains an applied pickling layer 16 on the surface 15 back, especially in areas of the adhesive, which has a low absorption capacity against the stain than the natural fiber. Likewise, this effect can be reversed by another, open-pored Klebertyp. The invention aims for a near-natural surface, so that only very thin pickling layers are produced by the pickling and the further processing steps 16 be generated, preferably in the range of 100 to 500 microns.

5 shows the surface 15 the material disc 14 after repeated pickling and sanding, as well as the application of a thin coat of varnish 18 which seals the surface and does not affect the feel and appearance of natural fibers. The paint used is a transparent clear coat or shellac, the sealing by a lacquer depending on the application is not necessary.

In the previous embodiments, the surface was 15 in each case over the entire surface in the same way by pickling, grinding and possibly painting have been processed. According to the embodiment accordingly 6 becomes a masking of the surface 15 used to areas with different pickling layer 16 ' . 16 '' to create and only partial areas of the surface with a varnish layer 18 to provide. Additionally is in 6 clarifies that for areas of the surface 15 with an aluminum foil 17 no coverage by a pickling layer by aftertreatment by means of grinding or masking during pickling 16 ' . 16 '' he follows.

Variations in the aforementioned structure of the composite block and the surface treatment, a variety of decorative elements are represented, 7 shows an embodiment with three layers of aluminum foil in the upper part and two layers of aluminum foil in the lower part. Furthermore, some of the adhesive layers are colored, resulting in further brightness / color effects. As in 7 indicated by the curvature, the material disc is bent about an axis perpendicular to the orientation of the layers of natural fiber. Depending on the incident light and a change in the viewing angle, interesting light effects can thus be generated on the surface of the decorative element.

In 8th the steps of an embodiment of the inventive method for producing a decorative element are given.

In a first step A several layers of natural fibers are provided. These layers are individually pre-pressed and wetted in a second step B with an adhesive, in which case the aluminum foils are introduced. There are two variants of the adhesive used, one first is transparent, the other dark colored. Between a part of the layers of natural fiber, the first adhesive, between another part of the layers of natural fiber, the second adhesive is introduced.

The adhesive-wetted layers of natural fibers are layered in a third step C to form a composite block and then pressed in a fourth step D. The degree of compression is between 20 and 90%, so that the resulting thicknesses of the layers of natural fiber are between 2 and 3 mm, preferably about 2.5 mm. In contrast, the thickness of the adhesive layers is only 0.05 to 1 mm, preferably between 0.1 and 0.6 mm. In the introduced metal foil, for example made of aluminum, layer thicknesses of 0.1 to 1 mm, preferably 0.4 to 0.6 mm are used. The hardness of the metal significantly determines the quality of the cross-sectional image. High hardness metals produce increased compression on adjacent layers when cut. It happens locally Deformation of these layers and / or fraying of the cut edge. Likewise, the metal layer can turn out of the layer composite or tip over. A soft metal, such as aluminum, reduces this effect, if this is not wanted.

From the compressed composite block, in a fifth step E, a material disc is separated along a layered surface of the composite block. This material disk has a thickness of 0.5 to 5 mm, preferably 1 to 2 mm. This thickness is substantially the same over the entire surface of the material disc, whereby, depending on the porosity of the materials used and the sharpness of the separating tool, preferably a knife, a rough surface of the material disc is produced.

This interface will be edited in the following steps. An intermediate step may be inserted in which first the surface is lightly ground to produce a more homogeneous, less pickle-receiving surface.

In a sixth step F, stain is applied, which penetrates into the materials and partially settles on the surface. In a seventh step G, the surface is ventilated, i. H. promoted the drying of the stain, so that in an eighth step I, the surface can be sanded. After grinding, surface cleaning may be added as an additional step to rid the surface of debris from abraded material.

The loop of these three steps F, G, I is thereby run through several times, with the pickling used in each case differing in their coloring and applied intensity. First mordanting layers appear darker and thicker due to the high absorption capacity of the base material. From a certain degree of saturation can not be absorbed, d. H. The stain volatilizes when venting, so that these later applied layers are thinner. Locally it can lead to the formation of islands smeared / glued surfaces.

How to 6 When executed, the number of loops on sub-surfaces may differ. By means of masking by masking or masking, some surface portions are stained and abraded more frequently than others.

At the conclusion of the surface treatment, a thin layer of lacquer is applied in a ninth step J, which seals the surface but haptically and optically preserves the porosity.

In order to use the material disc as a decorative element is then bent in a tenth step K, the material disc and glued in an eleventh step L on a panel. This gives a panel that is suitable for interior design, especially for the business field of aircraft or the premium range of motor vehicles.

It is also expedient to first bend the decorative element and stick it to the panel or component, and then carry out steps A to J. This one has a higher rigidity of the decorative element and facilitates the processing.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 102010028247 [0002, 0004, 0004, 0004]
• FR 2913028 [0002, 0003]

Claims (14)

Method for producing a decorative element ( 1 ) with the following process steps: • providing (A) several layers of natural substances ( 11 ), Wetting (B) at least a first layer of natural substance with a first adhesive ( 12 . 14 ), • Layers (C) of the layers of natural substances ( 11 ) to form a composite block ( 10 ), • pressing (D) the composite block ( 10 ), • separating (E) a material disc ( 14 ) along a layered surface ( 15 ) of the composite block ( 10 ), • pickling (F) a surface ( 15 ) of the material disc ( 14 ), and • sanding (I) the pickled surface ( 15 ). The method of claim 1, including the additional step of ventilating (G) the pickled surface prior to grinding (I). Method according to one of the preceding claims, in which the steps of pickling (F) and grinding (F) are carried out several times. Method according to one of the preceding claims, wherein the steps of pickling (F) and grinding (F) are carried out such that a layer thickness of the pickling of 100 to 1000 microns, preferably from 100 to 500 microns is achieved. Method according to one of the preceding claims with the additional step of painting (J) the pickled and ground surface ( 15 ). Method according to one of the preceding claims, in which (A) of the natural product ( 11 ) Natural fiber of hemp, jute, kenaf, sisal, flax, soy, cellulose, wood, paper or a mixture thereof is used. Method according to one of the preceding claims, in which the first adhesive ( 12 ) is colorless and another adhesive ( 14 ), the other layers of natural substances ( 11 ), is colored dark. Method according to one of the preceding claims, in which between two layers natural product ( 11 ) and bonded with adhesive a metal foil ( 13 ) are inserted. Method according to Claim 8, in which the metal foil ( 13 ) is made of aluminum and substantially thinner than the layer of natural material ( 11 ). Method according to one of the preceding claims, in which during the separation of the material disc ( 14 ) a layer thickness of 0.5-5 mm, preferably 1-2 mm, is achieved. Method according to one of the preceding claims, wherein during pickling (F) and / or grinding (I) not the entire surface ( 15 ), but only a non-masked portion. Method according to one of the preceding claims, with the additional steps of bending (K) the material disc ( 14 ) and the gluing (L) of the material disc ( 14 ) on a panel. The method of claim 12, wherein the bending is about an axis perpendicular to the orientation of the layers of the natural product ( 11 ). Decorative element consisting of several layers of natural substance ( 11 ), which have glue ( 12 . 14 ), produced by the method according to one of the preceding claims.

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