Trim or fitting part for a vehicle, containing a functional element, and method and form for its manufacture

Abstract

The invention relates to a trim or fitting part (1) for a vehicle, comprising at least one layer (2) of plastic material with protruding shapes or structures (4) on its rear side (3') and at least one flat functional element (5) of low thickness and with an arrangement (6) of wire(s) or (an) analogous elongated or linear conductive or resistive element(s) which is firmly connected to a supporting structure (7) which is porous or provided with gaps. The part (1) is characterized in that at least the arrangement (6) of wire(s) of each planar functional element (5) and preferably also the respective connected support structure (7) with planar extension in the form of a porous or interspersed layer on the back (3') of this layer (2) is / are at least partially integrated into and encapsulated by the plastic material (MP) that forms this layer (2), and in that at least one protruding shape or structure (4) on the at least one planar functional element (5) is materially connected to the layer (2).

Description

[0001] |The present invention relates to the field of parts with a planar extension containing electrical functional elements, the latter also having a planar extension and generally being formed by one or more (single- or multi-wire) electrical wires arranged according to patterns or formed in arrays so as to cover a given area on the part, and to the manufacture of such parts, in particular as interior or exterior trim and / or lining parts for vehicles.

[0002] In this context, the invention relates to an inner or outer covering or lining part containing such a functional element, as well as a method and a mold for its production.

[0003] The relevant trim, lining, or equipment parts include, for example, dashboards, door panels, center console panels, window pillars, interior roof panels and similar interior trim parts, interior and / or exterior mirrors, plastic body elements, radiator grilles, bumpers, etc.

[0004] The functional elements in question are of an activatable nature or produce the desired effect by the passage of an electric current or when exposed to electromagnetic waves, the linear element(s) responding to the passage of a current, exhibiting conductive or resistive properties. To be integrated into flat parts of limited thickness, these functional elements are generally thin, in the form of flat wire structures and with a planar extension (i.e., the wire element is arranged to cover a surface discontinuously, for example, in the manner of a spiral or flat serpentine). Furthermore, they must be positioned close to the visible surface of the part to satisfactorily perform their function, i.e., generally beneath the layer or body of the part providing or supporting the visible surface.

[0005] The functions in question, which include, for example, heating, lighting, detection and measurement in the vehicle interior, reception, transmission, and / or transmission of signals, control, etc., provide useful services and improve the comfort of users, drivers, and / or passengers. They generally require a connection to a power source or an electronic device for activation or operation.

[0006] The invention particularly relates to structural cladding components that may be flat or uneven (or in 3D), or partially flat and uneven, and have a small thickness relative to their planar extent. They consist mainly of self-supporting parts that are preferably substantially rigid at least locally, and have a flat or uneven shape, for example in 3D (three dimensions).

[0007] Numerous embodiments of such parts are already known (see, for example, FR-A-3132255), in particular comprising a prefabricated functional element bonded to a support or substrate layer of the part, and an overmolding of the functional element deposited on a layer to form a substrate incorporating, in one piece, elements for fixing and / or supporting the part (shaped portions of the lug or tab type or projecting anchoring or engagement points) or stiffening or structural reinforcement elements (for example, ribs or wings).

[0008] However, if these fastening, supporting or stiffening elements are formed directly on the back of the body or layer that is intended to accommodate the flat functional element, this inevitably hinders them locally (see Fig. 1: View of the rear of a trim part according to the state of the art).

[0009] This limitation is all the more problematic as the flat functional element on the one hand and the fastening, supporting or stiffening elements on the other hand each have to meet their own demands or requirements.

[0010] The former should have the largest possible surface area, especially for the heating, transmitting / receiving (antenna), detection, or lighting functions, and be easy to manufacture (currently, for example, for prefabricated functional elements in the form of a wire arrangement mounted on a carrier layer or sandwiched between two carrier layers) and easily attachable to the respective backing. In particular, a variety of shapes of the prefabricated flat functional element to adapt to different arrangements, shapes, and sizes of the fastening, support, or stiffening elements increases their production costs (lack of standardization, multiple tools, limited series on the production line, changes requiring production interruption).

[0011] As regards the fixing, support or stiffening elements, their number and location are often dictated by considerations relating to the rigidity of the in-situ assembly of the trim piece, the maintenance of a minimum gap between it and adjacent parts (if too far apart, this poses an aesthetic risk to the appearance) and the location of the anchoring or counter-support points or of the additional fixing formations in the vicinity of the in-situ assembly on the vehicle.

[0012] Furthermore, flexibility on the part production line is limited, and changes in the type of parts to be manufactured (with different arrangement configurations of the fastening, support or stiffening elements and shapes of the flat functional element) are time-consuming and have a strong impact on productivity.

[0013] The object of the present invention is to overcome these disadvantages and, in particular, to propose a part construction of the above-mentioned type with which the hindrance problems associated with the integration of a planar functional element can be overcome without significantly impairing the manufacturing process.

[0014] To this end, it relates to a trim or fitting part for a vehicle, preferably at least partially having a three-dimensional shape, comprising at least one layer of plastic material, optionally forming a substrate, and having a front or visible face and an opposite rear face, the part also comprising, on the one hand, protruding formations or structures on its rear face corresponding to that of the layer, and, on the other hand, at least one flat functional element of small thickness and comprising an assembly of wire(s) or similar elongated or linear conductive or resistive element(s), which is rigidly connected to a support structure which is porous or provided with interstices and has a flat extension, this part being characterized in thatthat at least the arrangement of wire(s) or the like of the or each planar functional element and preferably also the respectively connected support structure with planar extension in the form of a porous or interspaced layer on the back of this layer is (are) at least partially integrated into the plastic material forming this layer and encapsulated thereby, and in that at least one protruding formation or structure on the at least one planar functional element is materially connected to the layer.

[0015] The invention will be better understood thanks to the following description, which refers to preferred embodiments given as non-limiting examples and is explained with reference to the accompanying drawings in which: the Fig. 2A and Fig. 2B schematic plan views and sectional views according to AA (from Fig. 2A) of a thin prefabricated flat functional element intended to be integrated into a cladding part according to the invention; Fig. 3 is a plan and sectional view in the plane of a protruding formation of the rear of a trim part according to the invention, which comprises the Fig. 2 contains the functional element shown; Fig. 4A a partial view of detail B of the Fig. 3 is on a different scale; Fig. 4B is a plan view of a portion of the rear of a trim panel as shown in Fig. 2 to 4, but which contains a different functional element; the Fig. 5A, Fig. 5B, Fig. 5C and Fig. 5D are schematic sectional views of a mold according to the invention for carrying out the manufacturing process according to the invention, illustrating four successive steps of the process (steps shown: opening the mold; placing the functional element on the male part; closing the mold; injecting the hot liquid plastic material under pressure and waiting for curing); the Fig. 6A and Fig. 6B Partial views of detail C of Fig. 5B or detail D of Fig. 5D are on a different scale; the Fig. 7A, Fig. 7B and Fig. 7C is a schematic sectional view of a mold according to an embodiment of the invention for carrying out the manufacturing process according to the invention, illustrating three successive steps of the process (steps shown: opening the mold and the cavity in the male mold; placing the functional element on the male mold and inserting the end of its connecting portion into the cavity; closing the mold and the cavity and injecting the hot liquid plastic material under pressure).

[0016] The Fig. 3, Fig. 4, Fig. 6B and Fig. 7C show a trim or equipment part (1) for a vehicle, which preferably has at least a partially three-dimensional shape. This part (1) comprises at least one layer (2) of plastic material (MP), which optionally forms a substrate and has a front or visible side (3) and an opposite rear side (3'). This part (1) also has, on the one hand, protruding formations or structures (4, 4') on its rear side (3') corresponding to that of the layer (2), and, on the other hand, at least one flat functional element (5) of low thickness and with an arrangement (6) of wire(s) or (a) similar elongated or linear conductive or resistive element(s) (6'), which is rigidly connected to a support structure (7) that is porous or provided with gaps and has a flat extension.

[0017] The planar, flat arrangement (6) of wire(s) (6') of the or each flexible 2D functional element (5) can correspond either to a single functional unit occupying the entire surface of the arrangement and containing all of its components, or to at least two geographically and materially separate functional units (each corresponding to a section of the arrangement), these two units providing the same functions or not. Among the conceivable functions, the following can be mentioned in particular: heating, lighting, detection, control (with or without contact), signal transmission (transmitting and / or receiving antennas), energy transmission (electromagnetic induction), authentication, or other functionalities useful to the driver or passengers that can be activated electrically.

[0018] The assembly (6) of wire(s) or similar linear elements (6') is rigidly connected, for example by gluing, to the support structure (7), which is advantageously flexible and multiply perforated (textile, nonwoven, mesh) and resistant to the temperatures and pressures of the injection molding process. The assembly defines a functional area (14) on the latter. Alternatively, the elongated or linear element(s) (6') can be rigidly connected to the support structure (7), for example, by melting or welding during their application to the latter, or can be applied and rigidly bonded to it by pressure (for example, with conductive / resistant ink).

[0019] The projecting formations or structures (4, 4') may, for example, correspond to elements for fixing and / or supporting the part (formations of the tab or lug type or projecting anchoring or engagement points) or also to elements for stiffening or structural reinforcement (for example ribs or wings).

[0020] According to the invention, at least the arrangement (6) of wire (wires) or the like (6') of the or each planar functional element (5) and preferably also the respectively connected support structure (7) with planar extension in the form of a porous or interspaced layer on the back side (3') of this layer (2) is (are) at least partially integrated into the plastic material (MP) forming this layer (2) and encapsulated thereby, and at least one protruding formation or structure (4, 4') is materially connected to the layer (2) on the at least one planar functional element (5).

[0021] Through these arrangements, the invention makes it possible to accommodate, on the back side (3') of the layer (2) forming the body of the part (1), both protruding formations or structures (4, 4') and one or more planar functional elements (5), without any obstructions between the former and the latter. It is therefore possible to arrange the two types of elements without any restrictions in terms of space or extension. Furthermore, the cohesion and mechanical strength of the body of the part (1) are not compromised, and the manufacturing process is not significantly altered (compared to a part 1 without a planar functional element).

[0022] Naturally, the superposition or overlap between the protruding formation(s) or structure(s) (4, 4') and the planar functional element(s) (5) is only partial, and the aforementioned integration and encapsulation of the planar functional element(s) (5) may then only be partial, namely only opposite the protruding formation(s) or structure(s) (4, 4'). Outside of these overlapping areas, the integration and encapsulation may only affect one side of the planar functional element(s) (5), the one carrying the wire(s) or the like (6'), with the other side remaining visible on the surface on the back side (3'), while simultaneously being connected to the layer (2).

[0023] Advantageously, however, the or each planar functional element (5) is fully integrated into the plastic material (MP) forming this layer (2), close to and below the rear side (3'), and the at least one protruding formation or structure (4, 4') extending from the rear side (3') is formed integrally with the layer (2) by means of a material bond through the at least one planar functional element (5), which is provided with pores, gaps or similar passages distributed over its surface.

[0024] These arrangements not only ensure, if necessary, additional or supplementary electrical insulation of the wires (6') of the arrangement (6) by enclosing and inserting them into the insulating thermoplastic material forming the layer (2) and the formations (4, 4') - for example polypropylene, polycarbonate, PMMA or polyester - but also reinforce the structure of this layer by integrating a reinforcement (5).

[0025] Furthermore, a good cohesion of the functional element (5) in the layer (2), a lower risk of tearing and / or damage due to friction or tearing and a strength and resistance in the attachment of the protruding formations or structures (4, 4') are achieved, since there is no interruption of the flow of plastic material and no re-welding line (no interfaces and lower risk of breakage in these formations).

[0026] In the following, the terms “conductor” and “insulator” refer to the electrical properties of the materials in question and the term “reinforcement” refers to structural or mechanical reinforcement or stiffness reinforcement.

[0027] In order to ensure a simple connection to the vehicle's power supply, the at least one flat functional element (5) has a connecting or connection section (11) for its power supply and / or the transmission of electrical signals in the form of an elongated extension of the element (5) in question, which is only partially or not integrated into the layer (2) and extends freely from the rear side (3') of the latter.

[0028] According to a first embodiment of the invention, the front or visible side (3) of the layer (2) also forms the visible surface of the part (1), the latter consisting of a one-piece finished molded part with at least one protruding formation or structure (4, 4') and at least one integrated flat functional element (5). Due to integrated finishing during molding, the manufacturing process is simpler and the resulting part is more cost-effective.

[0029] According to a second embodiment of the invention, the front side (3) of the layer (2) can be partially or completely covered by at least one additional layer, namely at least one decorative layer or coating forming the visible surface of the part (1), wherein the layer (2) consists of a finished molded part with at least one integral protruding formation or structure (4, 4') and at least one integrated flat functional element (5). This embodiment allows greater freedom in choosing the finishing and appearance of the part, as well as its feel and comfort.

[0030] This additional layer, which is applied to the visible side of the layer (2) forming the body of the part (1), may consist, for example, of a textile, a skin, a film, a layer of paint or varnish (or both) or another covering layer, which is molded on, for example, in a second molding phase.

[0031] As the Fig. 5, Fig. 6 and Fig. 7 show by way of example, the invention also relates to a method for producing a trim or equipment part (1) for a vehicle which has an at least partially three-dimensional shape, in particular a part (1) as described above.

[0032] Such a part (1) comprises at least one layer (2) of plastic material (MP), which optionally forms a substrate and has a front or visible side (3) and a back side (3'), wherein the part (1) also comprises protruding formations or structures (4, 4') on its back side (3') corresponding to that of the layer (2), and at least one flat functional element (5) of low thickness and with an arrangement (6) of wire(s) or (an) analogous elongated or linear conductive or resistive element(s) (6'), which is firmly connected to a support structure (7) with a flat extension.

[0033] This method is characterized in that it consists in providing at least one prefabricated flat functional element (5), with its supporting structure having a flat extension, which is in the form of a porous or interspersed support layer (7), arranging this or each flat functional element (5) in an injection mold (8) having two complementary parts (8' and 8"), by placing it or them on the part of the mold (8') which forms the back (3') of the layer (2) and which has recesses or cavities (9, 9') for forming the protruding formations or structures (4, 4'), closing the mold (8) so as to form an injection chamber (10), injecting the hot plastic material (MP) in the liquid state into this chamber (10), also filling the recesses or cavities (9, 9'),by flowing the liquid injected plastic material (MP) through regions (5') of the or each planar functional element (5) extending over the openings (9") to the injection chamber (10) of the recesses or cavities (9, 9') until the injection chamber (10) and the recesses or cavities (9, 9') are full, and finally opening the mold (8) and, after sufficient curing of the plastic material (MP), removing the part (1) therefrom, which comprises the layer (2), the formations or structures (4, 4') formed in one piece with this layer (2), and the at least one planar functional element (5) firmly connected thereto,wherein at least the wire(s) or analogous conductive or resistive elements (6') of the latter are encapsulated by the plastic material (MP) at least in the regions (5') of the respective planar functional element (5). At least the aforementioned region(s) (5') of the element (5) are perforated by being provided with a plurality of passages of the pore or gap type.

[0034] The invention thus makes it possible to produce an improved part (1) which contains one or more flat functional elements (5) without making the production process more complex or significantly changing it (a single additional work step, the insertion of the element 5) or changing the shape.

[0035] More specifically, the method may consist of providing at least one flat functional element (5) whose array (6) of guide wire(s) (6') is rigidly connected to one side of the connected perforated support layer (7). The at least one flat functional element (5) in question may be arranged on the relevant part of the mold (8'), which advantageously forms the male part, so that it rests with its perforated support layer (7) on this part of the mold (8'). The entire array (6) of guide wire(s) (6') is thus substantially completely encapsulated and embedded in the plastic material (MP) when the injection chamber (10) and the recesses or cavities (9, 9') are full. The integration of the array (6) at least into the layer (2) ensures additional insulation, good cohesion of the element (5), and limits the risk of damage due to tearing or friction.

[0036] In order to obtain a body of the part (1) which is in one piece and which incorporates at least one element (5) in its structure, it is provided that the latter is arranged on the relevant part of the mold (8') in such a way that, when the injection chamber (10) and the recesses or cavities (9, 9') are full, this flat functional element (5) is completely embedded in the plastic material (MP) forming the layer (2), and that the at least one protruding formation or structure (4, 4') is formed in one piece with the layer (2) by means of a material bond provided by the at least one flat functional element (5). The absence of an interruption in the flow of plastic material and a rewelding line ensures greater tear resistance for the formations and structures (4, 4') and good cohesion of the element (5) in the layer (2) which contains it.

[0037] According to a first embodiment, the support layer (7) consists of a mesh or a woven or non-woven textile with a mesh size or porosity suitable for the passage of the plastic material (MP) injected in the liquid state, and composed of fibers or filaments whose constitutive natural or plastic material retains its structural coherence and is resistant to the temperatures and pressures of the injected hot plastic material (MP), the support layer (7) advantageously being positioned on the relevant part of the mold (8') in such a way that it is substantially completely integrated into the plastic material (MP) on the back surface (3') of the layer (2).

[0038] According to a first embodiment, the support layer (7) consists of a mesh or a woven or non-woven textile composed of fibers or filaments whose constitutive material is chemically compatible with and adheres to the plastic material (MP) forming the layer (2), said fibers or filaments possibly having a nature allowing at least partial penetration of the plastic material (MP) in the hot liquid state into their structure.

[0039] According to a third embodiment, the carrier layer (7) consists of a layer with a continuous structure, such as a skin, a foil or a film made of a natural, synthetic or metallic material, said layer being provided with distributed perforations or pores for the passage of the plastic material (MP) injected in the hot liquid state.

[0040] In the three variants mentioned above, the assembly formed by the support layer (7) and the assembly (6) of wire(s) or line(s) with conductive or resistive properties (6') and corresponding to a flat functional element (5), for example of the "heating mat" type, comprises at least one conductive or resistive component applied to a support layer that allows its processing, in particular its overmolding. This support layer, for example a film, a fabric, a tulle, or a nonwoven, can advantageously provide adhesion to the injected plastic material during overmolding and can also provide thermal protection if necessary. The choice of material forming the support layer can be determined in particular according to the geometry and thickness of the final part, but also the type of plastic material (MP).Its basic porosity can be modified by notching or perforation if necessary to promote suitable passage of the injected material.

[0041] To obtain a part (1) comprising electrical connection means on its rear side (3'), the method according to the invention can consist in providing at least one flat functional element (5) having a connection or terminal portion (11) for its power supply and / or the transmission of electrical signals in the form of an elongated extension of the element (5) in question, and in arranging this flat functional element (5) on the part of the mold (8') in question such that an extreme portion (11') of this elongated extension (11) is received in a sealed cavity (12) of the part of the mold (8'), at least during the injection phase and possibly during the curing phase of the plastic material (MP), the elongated extension (11) being positioned in the mold (8) such that, after the curing phase, it is embedded and encapsulated in the plastic material (MP) of the layer (2) through which it passes.except for its extremal section (11'), which extends beyond the back (3') of the layer (2). This facilitates electrical connection from the back of the part.

[0042] More precisely, it may be provided to provide at least one flat functional element (5), the elongated extension (11) of which is formed by a band (13) of the material forming the support layer (7), which preferably extends the latter in one piece and carries, with a fixed connection, transmission and / or supply lines (6") connected to the arrangement (6) of guide wire(s) (6'). In this way, a robust and structurally homogeneous element (5) is obtained which is easier to manufacture and whose connection means are formed integrally with the element itself.For the structural reinforcement of the majority, or even the entirety, of the layer (2), it can be provided that the support layer (7) extends beyond the peripheral contour of a functional area (14) of the considered planar functional element (5), which is defined by the arrangement (6) of conductive or resistance wire(s) (6'), for example on a majority of the back side (3') of the layer (2), or even on the entirety thereof, advantageously by forming a reinforcing reinforcement which is integrated into this layer (2).

[0043] In connection with the aforementioned first embodiment of the part (1), the manufacturing process can lead directly to a finished part after demoulding, wherein the visible or front side of the layer (2) forms the visible layer of the part (1).

[0044] In connection with the aforementioned second embodiment of the part (1), the manufacturing method may further comprise applying, either after curing in the mold (8) or subsequently after removal from the mold (8), at least one additional layer, namely at least one ornamental or decorative layer, to the visible side (3) of the layer (2), thus forming a substrate for partially or completely covering this side (3), said at least one additional layer forming at least a portion of the visible side of the part (1). This embodiment allows additional flexibility in the possibilities for choosing the appearance, feel, and comfort, independently of the manufacture of the layer (2).

[0045] As through the Fig.Finally, as illustrated by way of example in Figures 5 to 7, the invention also relates to a mold for carrying out the aforementioned manufacturing process, comprising two constituent parts (8', 8") which are movable relative to one another, namely a male mold (8') provided with the recesses or cavities (9, 9') for forming protruding formations or structures (4, 4') on the back side (3') of the layer (2) and therefore of the part (1), on the one hand, and a female mold (8") which defines the surface finish of the visible side (3) of the layer (2) and, optionally, of the part (1), on the other hand, these two constituent parts (8', 8") delimiting, by mutual cooperation, in the closed state of the mold (8), an injection chamber (10) containing the recesses or cavities (9, 9').

[0046] This mold (8) is characterized in that the male part (11') has at least one region for the indexed reception of at least one flat functional element (5) of low thickness and with an arrangement of guide wire(s) (6) that is firmly connected to a support structure (7) with a flat extension in the form of a perforated layer. Precise positioning of the functional element (5) in the mold and therefore in the layer (2) can be easily achieved.

[0047] According to an advantageous design feature, the mold (8) can have This arrangement also allows at least one cavity (12) for receiving an elongated extension (11) forming a connecting portion of the corresponding at least one flat functional element (5) placed on the male mold (11'), the cavity (12) having an opening (12') towards the injection chamber (10) and, on the other hand, a means (12") for tightly closing this cavity (12), more precisely its opening (12'), thus clamping the elongated extension (11) and isolating an extreme portion (11') thereof from the injection chamber (10). This arrangement makes it possible to obtain a free and easily accessible connection area of ​​the layer (2).

[0048] Naturally, the invention is not limited to the embodiments described and illustrated in the accompanying drawings. Modifications remain possible, particularly with regard to the nature of the various elements or by substituting technical equivalents, without thereby departing from the scope of the invention.

Claims

[1] Trim or trim part (1) for a vehicle, preferably at least partially having a three-dimensional shape, comprising at least one layer (2) of plastic material (MP), optionally forming a substrate, and having a front or visible side (3) and an opposite rear side (3'), the part (1) also comprising, on the one hand, protruding formations or structures (4, 4') on its rear side (3') corresponding to that of the layer (2), and, on the other hand, at least one flat functional element (5) of small thickness and comprising an arrangement (6) of wire(s) or similar elongated or linear conductive or resistive element(s) (6'), which is rigidly connected to a support structure (7) which is porous or provided with gaps and has a flat extension, the part (1) characterized byis that at least the arrangement (6) of wire (wires) or the like (6') of the or each planar functional element (5) and preferably also the respectively connected support structure (7) with planar extension in the form of a porous or spaced layer on the back (3') of this layer (2) is (are) at least partially integrated into the plastic material (MP) which forms this layer (2) and encapsulated thereby, and in that at least one protruding formation or structure (4, 4') on the at least one planar functional element (5) is materially connected to the layer (2). [2] Part (1) according to claim 1, characterized byin that the or each planar functional element (5) is fully integrated into the plastic material (MP) forming this layer (2), close to and below the rear side (3'), and in that the at least one protruding formation or structure (4, 4') extending from the rear side (3') is formed integrally with the layer (2) by means of a material bond through the at least one planar functional element (5), which is provided with pores, interstices or similar passages distributed over its surface. [3] Part (1) according to claim 1 or 2, characterized by that the at least one planar functional element (5) has a connecting or connection section (11) for its power supply and / or the transmission of electrical signals in the form of an elongated extension of the element in question (5), which is only partially or not integrated into the layer (2) and extends freely from the rear side (3') of the latter. [4] Part (1) according to one of claims 1 to 3, characterized by that the front or visible side (3) of the layer (2) also forms the visible surface of the part (1), the latter consisting of a one-piece finished molded part, with at least one protruding formation or structure (4, 4') and at least one integrated flat functional element (5). [5] Part (1) according to one of claims 1 to 3, characterized by that the front side (3) of the layer (2) is partially or completely covered by at least one additional layer, namely at least one decorative layer or a decorative coating which forms the visible surface of the part (1), wherein the layer (2) consists of a finished molded part, with at least one one-piece protruding formation or structure (4, 4') and at least one integrated flat functional element (5). [6] Method for producing a trim or equipment part (1) for a vehicle, which has an at least partially three-dimensional shape, in particular a part (1) according to one of claims 1 to 5, wherein this part (1) comprises at least one layer (2) of plastic material (MP), which optionally forms a substrate and has a front or visible side (3) and a rear side (3'), wherein the part (1) also has protruding formations or structures (4, 4') on its rear side (3') corresponding to that of the layer (2), and at least one flat functional element (5) of small thickness and with an arrangement (6) of wire (wires) or (an) analogous elongated or linear conductive or resistive element(s) (6') which is firmly connected to a support structure (7) with a flat extension, wherein the method characterized byis that it consists in providing at least one prefabricated flat functional element (5), with its supporting structure with a flat extension, which is in the form of a porous or spaced-apart support layer (7), arranging this or each flat functional element (5) in an injection mold (8) having two complementary parts (8' and 8"), by arranging it or them on the part of the mold (8') which forms the back (3') of the layer (2) and which has recesses or cavities (9, 9') for the formation of the protruding formations or structures (4, 4'), closing the mold (8) so as to form an injection chamber (10), injecting the hot plastic material (MP) in the liquid state into this chamber (10), also filling the recesses or cavities (9, 9') by forcing the liquid injected plastic material (MP) through areas (5') of the or any flat functional element (5),which extend over the openings (9"), to the injection chamber (10) of the recesses or cavities (9, 9') until the injection chamber (10) and the recesses or cavities (9, 9') are full, and finally to open the mold (8) and, after sufficient curing of the plastic material (MP), to remove the part (1) from it, which comprises the layer (2), the formations or structures (4, 4') which are materially formed in one piece with this layer (2), and the at least one flat functional element (5) which is firmly connected thereto, wherein at least the wire(s) or analogous conductive or resistive elements (6') of the latter are encapsulated by the plastic material (MP) at least in the regions (5') of the respective flat functional element (5). [7] Manufacturing method according to claim 6, characterized byin that it consists in providing at least one flat functional element (5), the arrangement (6) of which is made up of guide wire(s) (6') and is firmly connected to one side of the connected perforated carrier layer (7), and in that the at least one flat functional element (5) in question is arranged on the relevant part of the mold (8'), which advantageously forms the male part, so that it rests with its perforated carrier layer (7) on this part of the mold (8'), the entire arrangement (6) of guide wire(s) (6') being thus substantially completely encapsulated by the plastic material (MP) and embedded in it when the injection chamber (10) and the recesses or cavities (9, 9') are full. [8] Manufacturing process according to claim 6 or 7, characterized bythat the at least one planar functional element (5) in question is arranged on the relevant part of the mold (8') in such a way that, when the injection chamber (10) and the recesses or cavities (9, 9') are full, this planar functional element (5) is completely embedded in the plastic material (MP) that forms the layer (2), and that the at least one protruding formation or structure (4, 4') is formed integrally with the layer (2) by means of a material connection through the at least one planar functional element (5). [9] Manufacturing process according to one of claims 6 to 8, characterized byin that the support layer (7) consists of a mesh or a woven or non-woven textile with a mesh size or porosity suitable for the passage of the plastic material (MP) injected in the liquid state, and which is composed of fibers or filaments whose constitutive natural or plastic material retains its structural coherence and is resistant to the temperatures and pressure of the injected hot plastic material (MP), the support layer (7) being advantageously positioned on the relevant part of the mold (8') in such a way that it is substantially completely integrated into the plastic material (MP) on the back side (3') of the layer (2). [10] Manufacturing process according to one of claims 6 to 9, characterized byin that the support layer (7) consists of a mesh or a woven or non-woven textile composed of fibers or filaments whose constitutive material is chemically compatible with and adheres to the plastic material (MP) forming the layer (2), these fibers or filaments possibly having a nature allowing at least partial penetration of the plastic material (MP) in the hot liquid state into their structure. [11] Manufacturing process according to one of claims 6 to 10, characterized by that the carrier layer (7) consists of a layer with a continuous structure, such as a skin, a foil or a film made of a natural, synthetic or metallic material, the layer being provided with distributed perforations or pores for the passage of the plastic material (MP) injected in the hot liquid state. [12] Manufacturing process according to one of claims 6 to 11, characterized by in that it consists in providing at least one flat functional element (5) having a connection or terminal portion (11) for its power supply and / or the transmission of electrical signals in the form of an elongated extension of the element (5) in question, and in that this flat functional element (5) is arranged on the part of the mold (8') in question in such a way that an extreme portion (11') of this elongated extension (11) is received in a sealed cavity (12) of the part of the mold (8'), at least during the injection phase and possibly during the curing phase of the plastic material (MP), the elongated extension (11) being positioned in the mold (8) in such a way that, after the curing phase, it is embedded and encapsulated in the plastic material (MP) of the layer (2) through which it passes, except for its extreme portion (11') which extends beyond the back (3') of the layer (2). [13] Manufacturing method according to claim 12, characterized by that it consists in providing at least one flat functional element (5), the elongated extension (11) of which is formed by a band (13) of the material forming the support layer (7), which preferably extends the latter in one piece and carries, with a fixed connection, transmission and / or supply lines (6") connected to the arrangement (6) of guide wire(s) (6'). [14] Manufacturing process according to one of claims 6 to 13, characterized bythat the carrier layer (7) extends beyond the peripheral contour of a functional area (14) of the considered planar functional element (5) which is defined by the arrangement (6) of conducting or resistive wire(s) (6'), for example on a large part of the back side (3') of the layer (2), or even on the entirety thereof, advantageously by forming a reinforcing reinforcement which is integrated into this layer (2). [15] Manufacturing process according to one of claims 6 to 14, characterized by in that it consists in applying, either after curing in the mold (8) or subsequently after removal from the mold (8), at least one additional layer, namely at least one ornamental or decorative layer, to the visible face (3) of the layer (2) thus forming a substrate to partially or totally cover this face (3), this at least one additional layer forming at least a portion of the visible face of the part (1). [16] A mold (8) for carrying out the manufacturing process according to any one of claims 6 to 15, comprising two constituent parts (8', 8") movable relative to each other, namely a male mold (8') provided with the recesses or cavities (9, 9') for forming protruding formations or structures (4, 4') on the back side (3') of the layer (2) and therefore of the part (1), on the one hand, and a female mold (8") defining the surface finish of the visible side (3) of the layer (2) and optionally of the part (1), on the other hand, these two constituent parts (8', 8") delimiting, by mutual cooperation, in the closed state of the mold (8), an injection chamber (10) containing the recesses or cavities (9, 9'), this mold (8) characterized byis that the male part (11') has at least one area for the indexed reception of at least one flat functional element (5) of small thickness and with an arrangement of guide wire(s) (6) which is firmly connected to a support structure (7) with a flat extension in the form of a perforated layer. [17] Mold according to claim 16, characterized by in that it also has at least one cavity (12) for receiving an elongated extension (11) forming a connecting portion of the corresponding at least one flat functional element (5) placed on the male mold (11'), the cavity (12) having an opening (12') to the injection chamber (10) and, on the other hand, a means (12") for tightly closing this cavity (12), more precisely its opening (12'), whereby the elongated extension (11) can be clamped and an extreme portion (11') thereof can be isolated from the injection chamber (10). |

Images