Method for manufacturing a trim element with a decorative element, and associated trim element
Patent Information
- Application Number
- FR2024015273
- Authority / Receiving Office
- FR · FR
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2024-12-26
- Publication Date
- 2026-07-03
Smart Images
Figure 00000000_0000_ABST
Abstract
Description
Title of the invention: Method for manufacturing a trim element with a decorative element, and associated trim element
[0001] The present invention relates to a method for manufacturing a vehicle trim element, the trim element having a visible face with at least one decorative element, and an associated trim element.
[0002] Document DE102012016147 Al describes the realization of a trim element having a first decorative layer and a second decorative layer with decorative elements covering the entire visible surface, and comprising a reinforcing layer.
[0003] The process described in this document is complex. First, each of the decorative layers must be applied, and then the decorative elements are deposited onto the first decorative layer so that they adhere to it. Next, this assembly is placed in the mold where overmolding is performed by injection. Thus, this process comprises numerous steps.
[0004] Furthermore, the decorative elements are island-shaped, designed to be manufactured, manipulated, and placed on the first decorative layer: the process is not flexible with regard to the type of decorative elements desired. Indeed, it is not possible with this process to have small or, for example, very thin decorative elements, which would be difficult to handle.
[0005] The object of the invention is then to propose a simple manufacturing method for a trim element with at least one decorative element, of satisfactory aesthetic quality and such that at least one decorative element is as desired.
[0006] To this end, the invention relates to a method for manufacturing a vehicle trim element, the trim element having a visible face, the manufacturing method comprising the following steps:
[0007] - supply of a mold comprising a molding surface,
[0008] - arrangement of at least one decorative element on the molding surface, the at least a decorative element with at least one lateral surface,
[0009] - distribution of at least one wall, the at least one wall being distributed adjacently to at least part of at least one lateral surface, at least one wall being arranged on the molding surface, so that at least one decorative element and at least one wall only partially cover the molding surface, and
[0010] - introduction into the plastic material mold, so that the plastic material extends against the molding surface and at least one wall and possibly at least one decorative element
[0011] The manufacturing process is simple and comprises a reduced number of steps. The distribution of at least one decorative element on the molding surface allows for an aesthetically pleasing result with the decorative elements as desired. The distribution of at least one wall along the decorative element prevents the decorative elements from detaching from the molding surface or the displacement of certain pigments from the decorative elements to the side of the lateral surface against which they are applied during the plastic material introduction step.
[0012] According to other advantageous aspects of the invention, the method comprises one or more of the following features, taken individually or in all technically possible combinations:
[0013] - the plastic material and at least one wall are made of the same material, and advantageously with the same shade;
[0014] - the decorative element has two lateral surfaces and a top surface connecting the two lateral surfaces; the upper surface being opposite the molding surface, at least one wall extending, at least over a portion of the at least one decorative element, against the two lateral surfaces and the upper surface;
[0015] - at least one wall and at least one decorative element are made of materials of the same nature, more particularly polypropylene or acrylonitrile butadiene styrene;
[0016] - the arrangement of at least one decorative element and the distribution of at least a wall is produced by additive manufacturing.
[0017] - at least one wall is distributed simultaneously to at least one element decorative;
[0018] - the introduction of plastic material into the mold includes an injection of the plastic material in a molding cavity delimited by the molding surface;
[0019] - at least one wall and at least one decorative element are maintained at temperature between the distribution of at least one wall and the introduction of the plastic material; and / or
[0020] - the process includes a step of hardening the plastic material, and a step removal of the plastic-based filling element, at least one decorative element, and at least one mold wall
[0021] The invention also relates to a trimming clement obtained by a manufacturing process as defined above.
[0022] The invention will become clearer upon reading the following description, given solely by way of non-limiting example, and made with reference to the drawings in which:
[0023] [Fig-1] [Fig. 1] is a schematic representation of an example of a mold for the manufacturing process according to the invention,
[0024] [Fig.2] [Fig.2] is a schematic representation of a decorative element distribution step according to an example of a manufacturing process according to the invention,
[0025] [Fig.3] [Fig.3] is a schematic representation of a first wall distribution step according to the example of [Fig.2],
[0026] [Fig.4] [Fig.4] is a schematic representation of a second wall distribution step according to the example of [Fig.2],
[0027] [Fig.5] [Fig.5] is a schematic representation of a third-wall distribution step according to the example of [Fig.2],
[0028] [Fig. 6] [Fig. 6] is a schematic representation of a decorative element and walls on a molding surface according to an example of a manufacturing process according to the invention, and
[0029] [Fig.7] [Fig.7] is a schematic representation of a filling element obtained by the example process of [Fig.6].
[0030] The invention relates to a method for manufacturing a vehicle trim element, the trim element having a visible face
[0031] The manufacturing process comprises the following steps:
[0032] - supply of a mold comprising a molding surface,
[0033] - arrangement of at least one decorative element on the molding surface,
[0034] - distribution of at least one wall, and
[0035] - introduction into the plastic material mold.
[0036] An example of a mold 10 that can be used for the manufacturing process according to the invention is shown schematically in [Fig. 1].
[0037] The mold 10 has a molding surface 16.
[0038] In at least one mold configuration, the molding surface 16 delimits a molding cavity.
[0039] The mold 10 further includes a material inlet 18.
[0040] The material inlet 18 opens into the molding cavity.
[0041] The mold 10 comprises, for example, here, a plurality of mold parts 12, 14, here a first mold part 12 and a second mold part 14.
[0042] Each mold part 12, 14 comprises a portion of the molding surface 16.
[0043] The mold parts 12, 14 are movable relative to each other between an open configuration and a molding configuration.
[0044] In the open configuration, the mold parts 12, 14 are spaced apart from each other. The molding surface 16 is accessible.
[0045] In the molding configuration, the mold parts 12, 14 delimit the molding cavity. The mold parts 12, 14 extend against each other, so as to delimit said molding cavity.
[0046] The mold 10 is, for example, an injection mold, for example for injection overmolding.
[0047] Alternatively, the mold 10 is a rotomolding mold or an injection and blow molding mold, delimiting a molding cavity into which a preform is inserted, a fluid, for example air, being inserted into the preform, so as to blow the preform into the shape of the molding cavity.
[0048] At least one decorative element 118 is arranged, here distributed, on the molding surface 116 of the mold 110, more particularly here on the molding surface 116 delimited by the first part of the mold 112.
[0049] A schematic representation of an example of the arrangement step is shown in [Fig.2].
[0050] The distribution of at least one decorative element 118 is carried out by additive manufacturing or by extrusion of molten granules.
[0051] This is particularly advantageous for achieving any desired design.
[0052] More particularly, at least one decorative element 118 is distributed by a nozzle 120 onto the molding surface 116, more particularly only onto a part of the portion of the molding surface defined by one of the mold parts, here the first mold part.
[0053] The material inlet opens at the level of the molding surface delimited by another part of the mold, here the second part of the mold.
[0054] The nozzle 120 is able to move in relation to the molding surface 116, here in relation to the portion of the molding surface delimited by the first part of the mold, so as to deposit material, more particularly according to a desired pattern.
[0055] The material includes pigments. This gives at least one decorative element a desired color and shade.
[0056] The pattern includes, for example, veins and / or small spots.
[0057] The at least one decorative element 118 includes, for example, at least one line of material.
[0058] The material is, for example, heated upstream of the nozzle 120, so as to flow through the nozzle 120 onto the molding surface 116. The material is, for example, heated to a temperature between 160°C and 300°C.
[0059] The molding surface 116 is, for example, heated to a temperature between 20°C and 150°C.
[0060] At least one decorative element 118 is, for example, made of polypropylene (PP).
[0061] Alternatively, at least one decorative element 118 is made of styrene material, such as acrylonitrile butadiene styrene (ABS) or a polycarbonate and ABS mixture.
[0062] At least one decorative element 118 has at least one lateral surface 122, 124.
[0063] The lateral surface 122, 124 extends from the molding surface 116 in the opposite direction from said molding surface 116.
[0064] The lateral surface 122, 124 corresponds to one side of at least one decorative element 118 arranged on the molding surface 116.
[0065] Here, the decorative element 118 has two lateral surfaces 122, 124 and a top surface 126 connecting the two lateral surfaces, the top surface 126 being opposite the molding surface 116.
[0066] At least one wall 128, 130, 132 is distributed adjacent to at least a part of at least one lateral surface 122, 124.
[0067] That is to say, the assembly formed by the walls 128, 130, 132 is adjacent to at least a part of at least one lateral surface 122, 124.
[0068] At least one wall 128, 130, 132 is, for example, distributed by additive manufacturing.
[0069] A schematic representation of an example of this step is shown in Figures 3 to 5.
[0070] The material for making at least one wall 128, 130, 132 is, for example, heated upstream of the nozzle 120, so as to flow through the nozzle 120 onto the molding surface 116 or the upper surface 126. The material for making at least one wall 128, 130, 132 is, for example, heated to a temperature between 160°C and 300°C.
[0071] The molding surface 116 and the upper surface 126 are, for example, heated to a temperature between 20°C and 150°C.
[0072] At least one wall 128, 130, 132 is distributed on the molding surface 116, so that at least one decorative element 118 and at least one wall 128, 130, 132 only partially cover the molding surface 116, more particularly so that at least one decorative element 118 and at least one wall 128, 130, 132 only partially cover the portion of the molding surface 116 delimited by the corresponding part of the mold.
[0073] Here, at least one wall comprises at least one side wall 128, 130, the or each side wall 128, 130 being arranged against a side surface 122, 124 of at least one decorative element 118 on the molding surface 116.
[0074] The or each side wall 128, 130 is distributed on the molding surface 116, in a manner adjacent to at least one decorative element.
[0075] The or each side wall 128, 130 has a width, measured perpendicular to the corresponding side surface, for example of at least 0.4 mm.
[0076] The or each side wall 128, 130 extends, for example only, over a portion of the length of the decorative element 118, the length being considered according to the direction of distribution of the decorative element 118 by the nozzle 120.
[0077] On said portion, the or each lateral wall 128, 130 covers the corresponding lateral surface 122, 124.
[0078] In the case of a plurality of side walls, each side wall 128, 130 is, for example, distributed successively by the nozzle 120, as shown in figures 3 and 4.
[0079] In a particular embodiment, at least one wall 128, 130, 132 further comprises at least one upper wall 132, the upper wall 132 extending against the upper wall 126.
[0080] The upper wall or each upper wall 132 extends, for example only, over a portion of the length of the decorative element 118. On said portion, the upper wall or each upper wall 132 covers the upper surface 126. On said portion, the upper wall or each upper wall 132 extends in part against at least one side wall 128, 130, more particularly against a face of said side wall 128, 130 opposite the molding surface 116.
[0081] The upper wall or each upper wall 132 is, for example, distributed successively by the nozzle 120, after the distribution of the lateral wall or each lateral wall 128, 130, as shown in [Fig.5].
[0082] At least one wall 128, 130, 132 extends, for example, at least over a portion of at least one decorative element 118, here a portion of the length of the decorative element 118, against the two lateral surfaces 122, 124 and the upper surface 126, as shown in [Fig. 5].
[0083] Thus, on this portion, at least one decorative element 118 is surrounded by the walls 128, 130, 132 and the molding surface 116.
[0084] Additionally or alternatively, on a portion of at least one decorative element 118, here a portion of the length of the decorative element 118, at least one wall 128, 130, 132 extends, for example, only against the two lateral surfaces 122, 124.
[0085] Additionally or alternatively, on a portion of at least one decorative element 118, here a portion of the length of the decorative element 118, at least one wall 128, 130, 132 extends, for example, only against one of the two lateral surfaces 122, 124.
[0086] More specifically, the location of the wall(s) is adapted according to the desired visual effects.
[0087] The presence of a wall against a surface of the decorative element limits, or even avoids, the phenomenon of displacement of the material or pigments of the decorative element 118 during the introduction into the plastic material mold.
[0088] The displacement of the material of the decorative element 118 would correspond to a detachment of at least one decorative element from the molding surface 116 and its displacement, due to the force applied by the plastic material on the decorative element during its introduction into the mold.
[0089] The presence of a wall against a surface of the decorative element increases the contact area between the elements distributed prior to the introduction of the plastic material, and thus improves the cohesion of these elements, including at least one decorative element 118, to the molding surface 116.
[0090] In the case of pigment displacement of the decorative element 118, the pigments are carried along by the injected material flow which, in contact with the decoration, melts it and applies a force to it.
[0091] The presence of a wall prevents the plastic material from carrying part of the at least one decorative element towards said wall. This thus allows for a clear outline of the at least one decorative element.
[0092] A side wall is therefore, for example, distributed against at least one decorative element where a clean outline only is desired.
[0093] In some cases, a displacement of pigments is desirable for aesthetic reasons, in certain locations, so that no side wall is distributed against at least one decorative element in these locations.
[0094] An example of the arrangement on the molding surface 116 of a decorative element 118 and of walls 128, 130, 132 along the decorative element 118 is shown in [Fig.6].
[0095] Figure 6 also shows an example of the direction of introduction of the plastic material after the arrangement of the decorative element 118 and the walls 128, 130, 132, here from right to left.
[0096] At least one wall 128, 130, 132 and at least one decorative element 118 are made of materials of the same nature, more particularly of the same material.
[0097] This helps to promote mechanical connections between them.
[0098] The said material is not here of the same colour between the at least one wall 128, 130, 132 and the at least one decorative element.
[0099] The only difference between the materials of at least one wall 128, 130, 132 and at least one decorative element 118 is here the pigment(s) contained and their concentration in said material.
[0100] At least one wall 128, 130, 132 have the same material characteristics with each other, and furthermore with the introduced plastic material. More specifically, they are made of the same material.
[0101] This allows for a unified and uniform appearance.
[0102] At least one wall 128, 130, 132 is, for example, made of polypropylene (PP), similarly to at least one decorative element 118.
[0103] Alternatively, at least one wall 128, 130, 132 is made of styrene material, such as acrylonitrile butadiene styrene (ABS) or a polycarbonate and ABS mixture, similarly to at least one decorative element 118.
[0104] In an alternative embodiment, each decorative element 118 and the corresponding side wall(s) 128, 130 are distributed simultaneously on the molding surface according to the arrangement described above. If necessary, the upper wall 132 is, for example, distributed at a later stage.
[0105] More particularly, the nozzle 120 distributes on the molding surface 116 the material corresponding to the decorative element 118 and at least one side wall 128, 130 simultaneously, in one pass.
[0106] The mold is, for example, in the open configuration during the distribution of at least one decorative element 118 and at least one wall 128, 130, 132.
[0107] Between the distribution of at least one wall and the introduction of plastic material, at least one wall and at least one decorative element are, for example, kept at temperature.
[0108] The mold is then, for example, subsequently moved into the molding configuration.
[0109] The plastic material is then introduced into the mold 10, more particularly into the molding cavity, here through the material inlet 18.
[0110] The plastic material is introduced so that the plastic material extends against the molding surface 116 and at least one wall 128, 130, 132 and possibly at least one decorative element 118 if it is not surrounded.
[0111] At least one decorative element 118 and the side wall(s) 128, 130 remain against the molding wall 116 during the introduction of the plastic material.
[0112] More particularly, the plastic material is in fluid form, here molten, and is introduced so as to cover the assembly formed of at least one decorative element and at least one wall, and here also to fill the molding cavity.
[0113] The introduction of plastic material into the mold here involves injecting the plastic material into the mold cavity delimited by the molding surface. This introduction then corresponds, for example, to injection overmolding. The material introduced by injection overmolding has, for example, a temperature between 160°C and 300°C.
[0114] The plastic material and at least one wall 128, 130, 132 are made of the same material, and advantageously with the same color.
[0115] The plastic material is thermoplastic.
[0116] The plastic material is, for example, polypropylene (PP), similarly to at least one wall.
[0117] Alternatively, the plastic material is acrylonitrile butadiene styrene (ABS), similarly to at least one wall.
[0118] In an alternative embodiment to injection molding, the introduction of plastic material into the mold includes a step of introducing plastic material into the molding cavity through a material inlet, the mold being a rotomolding mold. The introduction of plastic material into the mold further includes setting the mold in motion, more particularly rotating the mold, to distribute the introduced plastic material over the molding surface and cover the assembly with at least one decorative element and at least one wall. More particularly, the introduced plastic material is in powder form. Thus, before rotating the mold, the plastic powder is heated to obtain a fluid plastic material that is evenly distributed over the molding surface.
[0119] In an alternative embodiment to injection overmolding and rotomolding, the introduction into the mold of plastic material includes a step of introducing a preform into an injection-blowing mold, the preform being made of a plastic material.
[0120] More specifically, the preform is heated after its introduction so as to be deformable by blowing. The preform is then, for example, heated to a temperature between 170°C and 230°C.
[0121] The introduction of plastic material into the mold then includes the introduction of gas, for example air, through the material inlet, arranged at the neck of the preform.
[0122] The preform is then blown until the walls of the preform extend against the molding surface and cover the whole formed by at least one decorative element and at least one wall.
[0123] The process further includes here a step of hardening the plastic material, and a step of removing the filling element formed of the plastic material, at least one decorative element and at least one wall, for example after moving the mold into the open configuration.
[0124] The hardening includes, for example, the cooling of the assembly formed of the plastic material, of at least one decorative element and of at least one layer of the mold, more particularly up to 50°C.
[0125] The mold no longer heats up during the hardening stage.
[0126] The plastic material, at least one decorative element and at least one layer The mold parts bond together during the introduction of the plastic material and / or hardening, so as to form the filling element.
[0127] Since the plastic material, at least one decorative element and at least one layer of the mold are made of a material of the same nature, the cohesion of the filling element is particularly strong.
[0128] At least one decorative element 118 is protruding from an external surface of the trim element. Thus, said external surface forms a visible face of the trim element having a decoration formed by at least one decorative element 118.
[0129] As explained previously, in locations where a partition has been arranged next to at least one decorative element, the decoration has a clear outline.
[0130] An example of a trim element 200, obtained with the arrangement shown in [Fig.6], is shown in [Fig.7].
[0131] In a particular embodiment, not shown, the molding surface is partially delimited by a removable shell.
[0132] More particularly, the mold includes at least one removable shell capable of being fixed, reversibly, to a part of the mold, so that the removable shell forms part of the molding surface.
[0133] At least one decorative element and at least one wall are distributed on the part of the molding surface formed by the removable shell.
[0134] Said distribution is, for example, carried out when the removable shell is separated from the mold part.
[0135] Then, the removable shell is fixed to the mold part before the introduction of the plastic material, more particularly so that the removable shell partially delimits the molding cavity during the introduction.
[0136] In a particular embodiment, the mold comprises several copies of at least one removable shell.
[0137] The process then includes, for example, simultaneously a step of making a first filling element in the mold equipped with a first copy of at least one removable shell, for example the introduction of plastic material into the mold, and the distribution of at least one decorative element and at least one wall on a second copy of at least one removable shell for making a second filling element.
[0138] This allows in particular the distribution of at least one decorative element and at least one wall to be carried out in masked time.
[0139] As soon as the first filling element is extracted from the mold fitted with the first example of the at least one removable shell, the second example of the at least one removable shell is attached to the mold part, so as to equip the mold of this second copy with at least one removable shell.
[0140] This makes it possible to produce trim elements using the process according to the invention more quickly.
Claims
Demands
1. A method for manufacturing a vehicle trim element, the trim element having a visible face, the manufacturing method comprising the following steps: - providing a mold (10; 110) comprising a molding surface (16; 116), - arranging at least one decorative element (118) on the molding surface (16; 116), the at least one decorative element (118) having at least one lateral surface (124, 126), - distributing at least one wall (128, 130, 132), the at least one wall (128, 130, 132) being distributed adjacent to at least a portion of the at least one lateral surface (124, 126), the at least one wall (128, 130, 132) being arranged on the molding surface (16; 116), such that at least one decorative element (118) and at least one wall (128, 130, 132) only partially cover the molding surface (16; 116), and - introduction into the mold (10;110) of plastic material, so that the plastic material extends against the molding surface (16; 116) and at least one wall (128, 130, 132) and possibly at least one decorative element (118).;
2. A method according to claim 1, wherein the plastic material and at least one wall (128, 130, 132) are made of the same material, and advantageously with the same shade.
3. A method according to claim 1 or 2, wherein the decorative element (118) has two lateral surfaces (124, 126) and a top surface (128) connecting the two lateral surfaces (124, 126), the top surface (128) being opposite the molding surface (116), the at least one wall (128, 130, 132) extending, at least over a portion of the at least one decorative element (118), against the two lateral surfaces (124, 126) and the top surface (128).
4. A method according to any one of claims 1 to 3, wherein at least one wall (128, 130, 132) and at least one decorative element (118) are made of materials of the same nature, more particularly of polypropylene or acrylonitrile butadiene styrene.
5. A method according to any one of claims 1 to 4, wherein the arrangement of at least one decorative element (118) and the distribution of at least one wall (128, 130, 132) are achieved by additive manufacturing.
6. Method according to claim 5, wherein at least one wall (128, 130, 132) is distributed simultaneously to at least one decorative element (118).
7. A method according to any one of claims 1 to 6, wherein the introduction into the mold (10; 110) of plastic material comprises an injection of the plastic material into a molding cavity delimited by the molding surface (16; 116).
8. A method according to any one of claims 1 to 7, wherein at least one wall (128, 130, 132) and at least one decorative element (118) are kept at temperature between the distribution of at least one wall and the introduction of the plastic material.
9. A method according to any one of claims 1 to 8, comprising a step of hardening the plastic material, and a step of removing the filling element formed from the plastic material, at least one decorative element (118) and at least one wall (128, 130, 132) of the mold (10; 110).
10. Filling element obtained by a manufacturing process according to any one of claims 1 to 9.