Trim panel for a vehicle interior

Abstract

The present invention relates to a part (1) of a trim panel for a vehicle interior, comprising: - a rigid support layer (2), wherein this support layer (2) predominantly contains at least one thermoplastic, in particular of the polypropylene type, - a coating layer (3), of the type textile nonwoven, which lies directly or indirectly over the carrier layer (2), wherein this coating layer (3) contains at least a mixture of thermoplastic fibers, of the type polypropylene or polyester, according to a physicochemical composition which differs from that of the carrier layer (2), characterized in that the mixture of the coating layer (3) also contains textile parts (30) which are arranged substantially in the plane of the coating layer (3).

Description

[0001] The present invention relates to the area of ​​trim panels for a vehicle interior and in particular to the area of ​​trim panels with reduced carbon content.

[0002] In light of current environmental challenges, the growing importance of environmental issues is forcing industry to reduce the carbon footprint of its manufactured products. The automotive industry, which has historically been closely linked to fossil fuels and the petrochemical industry, is compelled to consider its environmental impact. Incorporating environmental factors into the development of automotive products should help reduce CO2 emissions during the production of vehicle components.

[0003] Interior trim panels, which are also part of the automotive industry's product range, are likewise subject to efforts to optimize the carbon footprint. Solutions have been developed based on replacing materials with recycled ones to reduce the carbon footprint of the manufactured vehicle parts. However, the incorporation of recycled materials into vehicle parts is primarily hindered by safety requirements stipulated in the applicable standards in this area, but also, particularly for parts like interior trim, by aesthetic requirements that must comply with both manufacturers' specifications and commercial demands. Thus, not all vehicle parts permit the integration of recycled materials, especially for direct visual integration, or they may not permit it at all, or only to a very limited extent.

[0004] Solutions for incorporating recycled materials into vehicle parts have already been developed. Publication FR3139521 proposes a solution for recycling textiles by incorporating them into vehicle interior trim. This technology essentially involves shredding textiles into fibers, for example, by grinding or fiberizing, so that they can be easily mixed with various plastic components of vehicle interior parts. While effective, this solution is also demanding, as the various textiles to be recycled must first be shredded into a specific shape. This cumbersome preliminary step of shredding the textiles is therefore essential for the recycling process itself to be effective. Besides increasing energy consumption, this also extends the duration of the recycling process.

[0005] The present invention aims to overcome these disadvantages by proposing a panel element for a vehicle interior that facilitates the incorporation of at least one recycled material into a vehicle part, so that this incorporation retains the qualities of mechanical performance, use and safety on the one hand, and allows a variety of variations in appearance in response to any aesthetic requirements on the other.

[0006] The invention relates to a trim panel part for a vehicle interior, which includes: - a rigid support layer, wherein this support layer predominantly contains at least one thermoplastic, in particular of the polypropylene type, - a covering layer of the type textile nonwoven, which lies directly or indirectly over the carrier layer, wherein this covering layer contains at least a mixture of thermoplastic fibers, of the type polypropylene or polyester, according to a physicochemical composition which differs from that of the carrier layer, characterized in that the mixture of the covering layer also contains textile parts which are arranged essentially in the plane of the covering layer.

[0007] The invention also relates to a method for manufacturing a panel part according to the invention for a vehicle interior, characterized in that the method includes at least: - a phase of preparation of the coating layer, wherein this preparation includes at least one step of collecting and selecting textile parts intended for recycling, - a phase of joining and directly or indirectly attaching the coating layer to the substrate layer, characterized in that the phase of preparing the coating layer also includes: - a step of mixing textile parts with thermoplastic fibers, such as polypropylene and / or polyester, - a step of binding the mixture to obtain a textile-like nonwoven material, - a step in which the material is cut to the desired dimensions in order to execute at least a proportion of the coating layer of the part.

[0008] The invention will be better understood with the following description, which relates to preferred embodiments, given as non-limiting examples and explained with reference to the accompanying schematic drawings, in which: [ Fig. 1] shows a top view and a section through an example of a cladding panel part according to the invention, [ Fig. 2] a sectional view from the front through a panel section made of Fig. 1 represents, [ Fig. 3] shows a sectional view from the front through an example of a cladding panel part into which additional elements have been incorporated, [ Fig. 4] shows a sectional view from the front through an example of a cladding panel part into which a protective layer has been incorporated, [ Fig. 5] shows a frontal section view of an example of a cladding panel part in which textile parts are incorporated into the covering layer.

[0009] In this document, the term "thermoplastic" refers to a compound whose material is of synthetic origin, in particular plastic, which preferably has the structural form of a fiber and exhibits, on the one hand, a loss of stiffness under the influence of heat and, on the other hand, a hardening upon cooling.

[0010] In this document, the term "textiles" refers to all textiles, regardless of their type and / or origin.

[0011] The present invention relates to part 1 of a trim panel for a vehicle interior, comprising: - a rigid support layer 2, wherein this support layer 2 predominantly contains at least one thermoplastic, in particular of the polypropylene type, - a coating layer 3, of the type textile nonwoven, which lies directly or indirectly over the carrier layer 2, wherein this coating layer 3 contains at least a mixture of thermoplastic fibers, of the type polypropylene or polyester, according to a physicochemical composition which differs from that of the carrier layer 2, characterized in that the mixture of the coating layer 3 also contains textile parts 30 which are arranged substantially in the plane of the coating layer 3.

[0012] It should be noted that the inventive part 1 of the trim panel for a vehicle interior can be incorporated into any type of vehicle, in particular into land vehicles such as cars, trucks, commercial vehicles or construction vehicles, but also into the interior of aircraft or seacraft, especially if they can carry one or more passengers. For example, part 1 of the trim panel for a vehicle interior relates to a dashboard, a door or console panel, perhaps also to a ceiling light panel, a storage compartment or a frame for the windshield or window of the vehicle.

[0013] In the inventive Part 1 of the cladding panel, layers 2 and 3 are superimposed, each fulfilling the functions of a substrate and a coating, respectively. This makes Part 1 of the cladding panel suitable for use in vehicle interiors, while simultaneously enabling layered development using recycled materials, thus reducing the CO2 footprint of its production. Furthermore, the substrate layer 2 and the coating layer 3 of Part 1 of the cladding panel, given their respective compositions, are able to meet both safety requirements and aesthetic specifications in combination.

[0014] In the present invention, the thermoplastic fibers preferably consist of synthetic resins, in particular compounds used in the production of plastics. To optimize the CO2 footprint in vehicle production, the thermoplastic fibers used are preferably obtained from a plastics recycling chain. This optimization is achieved all the more because these thermoplastic fibers are infinitely recyclable due to their heat-dependent properties of "reversible thermoplasticity".

[0015] Due to the aforementioned properties of thermoplastic fibers, they have the advantage of being easily used as a matrix or binder in processes involving heating with temperature fluctuations or compression. These heating processes, in particular, make it possible to adapt the thermoplastic material during the production of the cladding panel part 1 by heating it to a temperature above the softening temperature of the thermoplastic fibers.

[0016] In the inventive part 1 of the cladding panel, the thermoplastic fibers of the carrier layer 2 are polypropylene compounds. These compounds optimally fulfill a compromise between mechanical performance, ease of manufacturing, and cost, while simultaneously meeting the specifications applicable to the vehicles. In contrast, the thermoplastic fibers for the coating layer 3 have a different physicochemical composition than the carrier layer 2 and are a combination of polypropylene and polyester. This difference in composition makes it possible to fulfill the structural and functional roles that each of these two layers 2 and 3 performs in part 1 of the cladding panel.The carrier layer 2 serves to support the coating layer 3, while the coating layer 3 provides an original and unique decorative surface capable of shaping the appearance of part 1 to meet users' aesthetic expectations and maintaining the stability of this appearance over time. A distinct physicochemical composition allows each layer to fulfill its function without compromising the structural requirements and physicochemical properties that part 1 of the cladding panel must meet.

[0017] According to an exemplary embodiment relating to a design variant of the inventive part 1 of the cladding panel, the material mixture of the covering layer 3 is made by combining, on the one hand, 5% to 15%, preferably in the order of 6% to 10%, ideally in the order of 8%, a mixture in equal or even similar proportions of co-extruded two-component fibers of polypropylene and polyester, and on the other hand, 20% to 40%, preferably in the order of 25% to 35%, ideally in the order of 30%, of polypropylene fibers, wherein the remainder of the material of the mixture is supplied by the textile parts 30 integrated into the covering layer 3.

[0018] Preferably, the thermoplastic material of the coating layer 3 is made of co-extruded two-component fibers of polypropylene and polyester, each fiber containing a polypropylene core surrounded by a polyester sheath. Since the melting point of the polyester sheath is lower than that of the polypropylene core, the polyester can fuse, and thus the thermoplastic fibers can be joined to each other and to the textile parts 30 in the coating layer 3, without the polypropylene core melting. The bonding of the polyester alone creates cohesion between the fibers and the textile parts 30. Under these conditions, the polyester acts as a binder for joining the polypropylene of the fibers to the textile parts 30. The melting temperature used can then be between 160° Celsius and 170° Celsius.

[0019] Within the scope of the invention, the support layer 2 thus exhibits higher mechanical stiffness properties than the coating layer 3. Under these conditions, the support layer 2 fulfills its load-bearing function by providing structural stiffness to the inventive part 1 of the cladding panel without altering or impairing the specific technical properties inherent in the coating layer 3.

[0020] Introducing textile parts 30 in a simply cut or torn form, without requiring a state corresponding to a fully degraded textile in a fiberized form, allows the textile parts 30 to be used in a format that approximates their native state. This eliminates the need for a milling or fiberizing process to prepare the textile parts 30 and thus provides a solution to industrial requirements for the production of cladding panel parts 1 that require a reduced carbon footprint. When manufacturing a cladding panel part 1, and in particular its coating layer 3, eliminating the need to mill or fiberize the textile parts 30 shortens the manufacturing process and significantly limits the amount of energy required to prepare these textile parts 30.

[0021] The textile parts 30 generally have flexible and essentially flat structures. Even as a component of a part 1 of the cladding panel according to the invention, these textile parts 30 can be easily arranged in the plane of the coating layer 3 of the part 1 of the cladding panel. Furthermore, given their flexible properties, the textile parts 30 are able to readily accommodate and adapt to any curvatures and surface variations of the coating layer 3. The textile parts 30 are arranged such that they are spread out in the coating layer 3 in such a way that they are positioned on the surface of the coating layer 3 and / or within its depth or thickness.Furthermore, due to their flexibility, the textile parts 30 can also have, on the one hand, a first part that is positioned at the level of the surface of the coating layer 3, and on the other hand, a second part that is set deeper in the thickness of the coating layer 3.

[0022] By incorporating the textile parts 30 into the interior of the coating layer 3 in combination with the polypropylene-polyester mixture, positioning can be achieved and maintained within the thickness of the coating layer 3, particularly at a defined depth. The textile parts 30 are then embedded in the polypropylene-polyester mixture. Preferably, the thermoplastic mixture of the coating layer 3, which combines polypropylene and polyester, incorporates a structural binder that is at least substantially transparent or even translucent, i.e., it allows at least the visible spectrum of light to pass through this thermoplastic mixture. Under these conditions, the textile parts 30 embedded in the thermoplastic material of the coating layer 3 remain visible from the outer surface of part 1 of the cladding panel through the transparent or translucent thermoplastic material.The textile components 30 thus contribute to the optical, indeed even aesthetic, appearance of the outer surface of the coating layer 3. The thermoplastic compound of the coating layer 3, which forms the material in which the textile components 30 are embedded, enables the creation of an outer surface of the coating layer 3 that is stiff and resistant despite the optical appearance achieved by the textile components 30.

[0023] According to an exemplary embodiment relating to a design variant of the inventive part 1 of the cladding panel, the textile parts 30 of the covering layer 3 are arranged at least partially overlapping one another. Thus, when these textile parts 30 are spread out on the plane of the covering layer 3, they can be positioned at respective depth levels that differ from the thickness of the covering layer 3.Under these conditions, if the distribution of the various textile parts 30 within the coating layer 3 is irregular, they are caused to overlap, such that, for example, a first portion of a textile part 30 lies above a second textile part, and a second portion of the same textile part 30 is positioned below a third textile part. The first and second portions of the textile part 30 may be at the same or different heights in the thickness of the coating layer 3. It should also be noted that the irregular appearance of the distribution of the textile parts 30 can be further enhanced by the variations in shape and size assumed by each of the different textile parts 30.The appearance achieved in this way by the various textile parts 30 set up in the coating layer 3 is then that of a patchwork quilt of textiles embedded in the thermoplastic mixture of the coating layer 3.

[0024] According to an exemplary embodiment relating to a further design variant of the inventive part 1 of the cladding panel, which can be combined with one of the previously described design variants, the textile parts 30 of the coating layer 3 are arranged such that they are distributed over the entire surface of the coating layer 3. According to this design variant, the translucent and / or transparent nature of the thermoplastic mixture of the coating layer 3 then enables the design of a coating layer 3 of the part 1 of the cladding panel whose optical appearance is completely reproduced by the various textile parts 30.Since the distribution of the textile parts 30 takes place on different levels of the coating layer 3, the translucent and / or transparent property of the thermoplastic mixture that embeds these textile parts 30 makes it possible to give the coating layer 3 an optical depth, especially if the difference in the positioning height between two sections of textile parts 30 that lie next to each other in the thickness of the coating layer 3 is significant.

[0025] According to an exemplary embodiment relating to a further design variant of the inventive part 1 of the cladding panel, and representing an alternative to the previously described design variant, the textile parts 30 of the coating layer 3 are arranged such that areas without textile parts 30 remain at certain locations on the surface of the coating layer 3. According to this design variant, the translucent and / or transparent nature of the thermoplastic compound of the coating layer 3 allows optical access to the surface of the material layer on which the coating layer 3 is positioned at those areas of the coating layer 3 that are free of textile parts 30. The surface of the material layer on which the coating layer 3 is positioned is thus able to indirectly contribute to the optical appearance of the inventive part 1 of the cladding panel via the thermoplastic material.Furthermore, depending on the thickness of the coating layer 3, the optical appearance of the coating layer 3 can also reveal a depth through the translucent and / or transparent character of the thermoplastic mixture in which the textile parts 30 are embedded, especially if the height difference between the positioning of the textile parts 30, which are positioned on the surface, and the surface of the material layer on which the coating layer 3 is positioned is significant.

[0026] According to an exemplary embodiment relating to a further design variant of the inventive part 1 of the cladding panel, which can be combined with one of the previously described design variants, the coating layer 3 has an average thickness of less than 10 millimeters, preferably between 2 and 8 millimeters, before its possible pressing or thermal pressing. The thickness of this coating layer 3 is at least greater than the thickness of a textile part 30 that is to be incorporated into the coating layer 3. Preferably, this thickness is at least twice the thickness, so that two adjacent textile parts 30 can overlap at least partially.Depending on the thickness of this coating layer 3, the translucent and / or transparent thermoplastic mixture in which the textile parts 30 are embedded will be able to create an optical appearance of depth on the surface of part 1 of the cladding panel.

[0027] According to an exemplary embodiment relating to a further design variant of the inventive part 1 of the cladding panel, which can be combined with one of the previously detailed design variants, the part 1 of the cladding panel includes an intermediate layer 6 positioned between the coating layer 3 and the carrier layer 2, wherein this intermediate layer 6 is arranged such that it covers the entire surface of the carrier layer 2. This intermediate layer 6 thus covers the carrier layer 2, so that if the thermoplastic material of the coating layer 3 is translucent and / or transparent, the surface of the intermediate layer 6 can be visible through the coating layer 3 between different textile parts 30, thus allowing the intermediate layer 6 to contribute to the optical appearance of the inventive part 1 of the cladding panel.This intermediate layer 6 can take the form of a film or a textile, e.g. a printed and / or dyed textile, so that an optical effect through transparency is possible through a portion of the coating layer 3.

[0028] According to an exemplary embodiment relating to a further design variant of part 1 of the cladding panel according to the invention, which can be combined with the previously detailed design variant, the intermediate layer 6 contains at least a mixture of thermoplastic fibers, such as polypropylene or polyester, and fibers from shredded textiles. For example, these shredded textile fibers can be fibers of natural or synthetic origin, such as polyethylene, polyester, flax, hemp, kenaf, myscanthus, wool, elastane, cotton, and polyamide fibers.

[0029] According to an exemplary embodiment relating to a further design variant of the inventive part 1 of the cladding panel, which can be combined with one of the previously described design variants, the coating layer 3 comprises an outer surface 31 that faces the opposite surface of the carrier layer 2, which includes at least one relief and / or has a non-smooth arrangement. A non-smooth arrangement corresponds in particular to a surface relief that is not visually perceptible but is detectable upon touching the outer surface 31, so that, for example, a graininess or roughness of this surface 31 can be felt.According to one embodiment, the coating layer 3 can have a relief on its outer surface 31 that is visible to users of the part 1 of the cladding panel, achieved, for example, by embossing or graining, and contributes to the aesthetic appearance of the part 1 of the cladding panel. According to another embodiment, the coating layer 3 can have a non-smooth arrangement on its outer surface 31 that is visible to users of the part 1 of the cladding panel, for example, in the form of surface graining. Thus, thanks to an environmentally friendly, low-carbon development process involving partial or complete manufacturing with textile components 30 from a recycling chain, the part 1 of the cladding panel according to the invention can have a coating layer 3 that combines an aesthetic appearance with reliefs and / or a non-smooth arrangement.

[0030] According to an exemplary embodiment relating to a further design variant of the cladding panel part 1 according to the invention, which can be combined with one of the previously detailed design variants, part 1 also includes a protective layer 4 positioned on at least a portion of the outer surface 31 of the coating layer 3, i.e., opposite the surface of the coating layer that is oriented towards the carrier layer 2, wherein this protective layer 4 can be at least partially transparent or translucent. This protective layer can, for example, be a protective lacquer, a colored lacquer, or a film. Such a protective layer 4 makes it possible to optimize the preservation of the outer surface 31 of the coating layer 3 over time by protecting it, in particular, from the risks of damage associated with its use.This protective layer 4 can also complement the optical appearance of the outer surface 31 according to its own appearance, so that the specific properties of the appearance or color of this protective layer 4 can be combined with the inherent properties of the outer surface 31 to effect an optical change in the appearance of the coating layer 3. For example, this protective layer 4 can give at least a portion of this outer surface 31 of the coating layer 3 a special hue or a glossy appearance, thereby introducing an additional decorative or textured motif.

[0031] The invention also relates to a method for manufacturing a part 1 of the trim panel for a vehicle interior according to the invention, wherein the method comprises at least: - a phase of preparation of the coating layer 3, wherein this preparation includes at least one step of collecting and selecting textile parts 30 that are intended for recycling, - a phase of joining and directly or indirectly attaching the coating layer 3 to the carrier layer 2, characterized in that the preparation phase of the coating layer 3 also includes: - a step of mixing textile parts 30 with thermoplastic fibers, such as polypropylene and / or polyester, - a step of binding the mixture to obtain a textile-like nonwoven material, - a step in which the material is cut to the desired dimensions in order to execute at least a proportion of the coating layer 3 of part 1.

[0032] According to one embodiment relating to a specific variant of the preparation phase for the coating layer 3, the step of mixing textile parts 30 with thermoplastic fibers is carried out by air circulation. This mixing step of the textile parts 30 employs AIRLAID's so-called "airflow" technology, which consists of an aerodynamic process in which the textile parts 30 containing the thermoplastic fibers of the mixture are transported and distributed in an airflow for subsequent bonding.

[0033] According to an exemplary embodiment relating to another variant of the implementation of the method according to the invention, which can be combined with one of the variants described above, the binding step of the mixture is carried out by heating and rolling and / or calendering the mixture. Heating the mixture of the textile parts 30 and the thermoplastic fibers supplies thermal energy, in particular to fuse the thermoplastic fibers in order to embed the various textile parts 30, so that the entire mixture forms a textile-like nonwoven material after heating. As an example of implementation, the heating process is carried out at a temperature of 160° Celsius to 170° Celsius to bring about the fusion of at least a portion of the thermoplastic material that is to form the coating layer 3.Preferably, this heating process of the mixture is supplemented by rolling and / or calendering of this mixture, so that the various components of the coating layer 3, which combine the textile parts 30 and the thermoplastic fibers, are pressed into a dense structure. The rolling and / or calendering of the coating layer 3 can be carried out by positioning a roller against a surface of the mixture that is to form the coating layer 3, or by positioning the mixture between two closely spaced rollers in counter-rotation. This at least one positioned roller can also be a heated roller, which makes it possible to also carry out the heating process of the mixture, or possibly to optimize the lamination process, or even to supplement the heating process during the lamination or calendering of the mixture.

[0034] According to an exemplary embodiment relating to another variant of the implementation of the method according to the invention, which can be combined with any of the variants described above, the recycled textile parts 30 have a size in the range of 3 mm to 120 mm and the thermoplastic fibers have a size in the range of 2 to 20 mm. It should be noted that the size of the textile parts 30 is essentially determined by the prior cutting of the textiles, which takes place before the textile parts 30 are mixed with the thermoplastic material. Preferably, the recycled textile parts 30 have dimensions in the range of 20 mm to 60 mm. The selection of the size of the textile parts 30 is also defined depending on the desired optical appearance of the surface of the coating layer 3.

[0035] According to an exemplary embodiment, which relates to a further variant of the implementation of the method according to the invention and can be combined with one of the variants described in detail above, the following takes place during the phase of joining the coating layer 3 to the carrier layer 2: - one step of positioning the coating layer 3 in a mold, - a thermal pressing process.

[0036] In the positioning step, the coating layer 3 is positioned relative to the substrate layer 2. During the thermal compression process, the thermoplastic material is melted, specifically by heating to almost 200°C. The adaptable structure of the two superimposed layers 2 and 3 is then formed by compression before being cooled to room temperature. Alternatively, the substrate layer 2 is heated before the coating layer 3 is positioned and the forming step is carried out during the thermal compression process.

[0037] According to a specific implementation example of this first embodiment, the surface of the mold that comes into contact with the coating layer 3 has a relief with a pattern or surface granulation. This pattern then makes it possible to create at least one visible, non-smooth relief and / or arrangement on the outer surface 31 of the coating layer 3 during the thermal pressing process. In addition, with regard to the implementation of a thermal pressing process, the step of prior mixing can be applied to textile fibers, thermoplastic fibers, and reinforcing fibers, so that these reinforcing fibers increase the mechanical strength properties of part 1 of the cladding panel.

[0038] According to a further supplementary example of the specific implementation of this first variant, the thermal pressing process in the mold involves pressing at a pressure on the order of 10 bar and a temperature on the order of 200°C. Such a non-restrictive implementation example allows for the subsequent demolding of part 1 of the cladding panel without any problems.

[0039] According to an embodiment of the inventive method, which relates to a specific variant of the first embodiment of the joining phase of the coating layer 3 to the carrier layer 2, the inventive method also includes an overmolding process of at least one additional element 5, wherein this additional element 5 can be a reading mark, a fastening element, a clip, or a rib. Preferably, the additional elements 5 are positioned on the side opposite the carrier layer 2. Additionally, these additional elements 5 are made of injection-molded thermoplastic resin, such as polypropylene.

[0040] According to an exemplary embodiment relating to a second embodiment of the phase of joining the coating layer 3 with the carrier layer 2, at least one injection of material takes place in this phase. This injection is preferably carried out on the surface of the coating layer 3 that faces the carrier layer 2.

[0041] According to a particular embodiment of this second embodiment variant, the phase of joining the coating layer 3 to the carrier layer 2 takes place at least as follows: - one step of positioning the coating layer 3 in a mold, - a step in which the material that is to form the carrier layer 2 is injected into the mold in order to over-inject the coating layer 3 over the carrier layer 2.

[0042] According to a preferred implementation example of this second embodiment of the assembly phase, the process of injecting material into a mold which may have a relief and / or a non-smooth arrangement is carried out to interact with an injected material based on a thermoplastic resin, in particular of the polypropylene type, which is intended to form the carrier layer 2.

[0043] According to an example relating to a further variant of the manufacturing process according to the invention, which can be combined with the other variants described in detail above, at least one bonding and / or coating process takes place during the joining of the coating layer 3 to the carrier layer 2 using at least one adhesive material and / or an adhesive. As a result of implementing this variant, the part 1 of the cladding panel contains, after joining, at least one intermediate layer of adhesive or adhesive, which is formed between the carrier layer 2 and the coating layer 3. Preferably, the adhesive material or adhesive selected for this process is polyurethane, polyamide, or polyester.

[0044] According to an exemplary embodiment relating to a further embodiment of the manufacturing process according to the invention, which can be combined with the various previously described variants, the process also includes a step for positioning and fixing a protective layer 4 on at least a portion of the outer surface 31 of the coating layer 3, i.e., opposite the surface of the coating layer 3 that is positioned opposite the carrier layer 2. According to a preferred implementation of this positioning and fixing step, the protective layer 4 is positioned so that it covers the entire outer surface 31, thus protecting the entire portion of the coating layer 3 that is visible to users. According to a specific example of this embodiment, the protective layer 4 is applied to the outer surface 31 by spraying with a sprayer or by using a brush or roller.Preferably, but not exclusively, the protective layer 4 consists of a protective lacquer, colored lacquer, or a transparent protective film that protects the optical and structural appearance of the outer surface 31 of the coating layer 3 of part 1 of the cladding panel. According to a particular example, various decorative elements can be incorporated into the transparent film by means of printing processes such as inkjet or pad printing to complete the effect achieved by the coating layer 3 of part 1 of the cladding panel.

[0045] In one implementation of the inventive method, which includes a phase of joining the coating layer 3 to the carrier layer 2, during which a thermal pressing process takes place according to the first embodiment described in detail above, the positioning and fastening of this transparent film to the coating layer 3 can be carried out after the thermal pressing process if the protective layer 4 is designed as a transparent protective film. This positioning and fastening of the transparent film then takes place when the outer surface 31 of the coating layer 3 is still hot, in particular at a temperature in the range of 170°C to 200°C. In such an implementation, the film withstands at least partial fusion of material under the influence of the residual heat from the thermal pressing process and adheres to the outer surface 31 of the coating layer 3.Under these conditions, a possible additional heating step, intended to optimize the adhesion of the protective layer 4 to the coating layer 3, can be omitted during the implementation of the process. The CO2 footprint of the manufacturing process according to the invention is thereby reduced accordingly.

[0046] 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 replacing them with technical equivalents, without thereby departing from the scope of protection of the invention. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] FR 3139521

[0004]

Claims

[1] Part (1) of a trim panel for a vehicle interior, comprising: - a rigid support layer (2), wherein this support layer (2) predominantly contains at least one thermoplastic, in particular of the polypropylene type, - a coating layer (3) of the type textile nonwoven, which lies directly or indirectly over the carrier layer (2), wherein this coating layer (3) contains at least a mixture of thermoplastic fibers of the type polypropylene or polyester, according to a physicochemical composition which differs from that of the carrier layer (2), characterized by , that the mixture of the coating layer (3) also contains textile parts (30) which are essentially arranged in the plane of the coating layer (3). [2] Part (1) according to claim 1, characterized by , that the textile parts (30) of the covering layer (3) are arranged at least partially overlapping each other. [3] Part (1) according to one of claims 1 or 2, characterized by , that the textile parts (30) of the coating layer (3) are arranged such that they are distributed over the entire top surface of the coating layer (3). [4] Part (1) according to one of claims 1 or 2, characterized by , that the textile parts (30) of the coating layer (3) are arranged such that areas free of textile parts (30) remain at certain points on the top surface of the coating layer (3). [5] Part (1) according to any of the preceding claims, characterized by , that the material mixture of the coating layer (3) is made by combining 5% to 15% of a mixture in equal or similar proportions of coextruded two-component fibers of polypropylene and polyester on the one hand and 20% to 40% polypropylene fibers on the other hand, wherein the remainder of the material of the mixture is added by the textile parts (30) incorporated into the coating layer (3). [6] Part (1) according to any of the preceding claims, characterized by, that the coating layer (3) has an average thickness of less than 10 millimeters. [7] Part (1) according to any of the preceding claims, characterized by that the part (1) of the plate contains an intermediate layer (6) positioned between the coating layer (3) and the support layer (2), wherein this intermediate layer (6) is arranged such that it covers the entire surface of the support layer (2). [8] Part (1) according to claim 7, characterized by , that the intermediate layer (6) contains at least a mixture of thermoplastic fibers, such as polypropylene or polyester, and fibers from shredded textiles. [9] Part (1) according to any of the preceding claims, characterized by , that the coating layer (3) contains an outer surface (31) which is opposite the surface of the carrier layer (2) which includes at least one relief and / or has a non-smooth arrangement. [10] Part (1) according to any of the preceding claims, characterized by that the part (1) also includes a protective layer (4) which is positioned on at least a portion of the outer surface (31) of the coating layer (3), i.e. opposite the surface of the coating layer which is positioned opposite the carrier layer (2), wherein this protective layer (4) may be at least partially transparent or translucent. [11] Method for manufacturing part (1) of a trim panel for a vehicle interior according to any one of claims 1 to 10, wherein the method comprises at least: - a preparation phase of the coating layer (3), wherein this preparation includes at least one step of collecting and selecting textile parts (30) intended for recycling, - a phase of joining and directly or indirectly attaching the coating layer (3) to the substrate layer (2), characterized by, that the preparation phase of the coating layer (3) also includes: - a step of mixing textile parts (30) with thermoplastic fibers, such as polypropylene and / or polyester, - a step of binding the mixture to obtain a textile-like nonwoven material, - a step in which the material is cut to the desired dimensions in order to execute at least a proportion of the coating layer (3) of the part (1). [12] Manufacturing process according to claim 11, characterized by , that the step of mixing textile parts (30) with thermoplastic fibers is carried out by air circulation. [13] Manufacturing process according to one of claims 11 or 12, characterized by that the step of binding the mixture is carried out by heating and rolling and / or calendering the mixture. [14] Manufacturing process according to one of claims 11 or 12, characterized by, that on the one hand the recycled textile parts (30) have dimensions on the order of 3 to 120 mm and on the other hand the thermoplastic fibers have dimensions on the order of 2 to 20 mm. [15] Manufacturing process according to one of claims 11 and 14, characterized by , that during the phase of joining the coating layer (3) on the carrier layer (2) the following takes place: - a step of positioning the coating layer (3) in a mold, - a thermal pressing process. [16] Manufacturing process according to claim 15, characterized by , that the process also includes a step of back-injecting at least one additional element (5), wherein this additional element (5) may be a reading mark, a fastening element, a clip or a rib. [17] Manufacturing process according to one of claims 11 and 14, characterized by, that at least one material injection process takes place during the phase of joining the coating layer (3) to the carrier layer (2). [18] Manufacturing process according to one of claims 11 and 14, characterized by , that in the phase of joining the coating layer (3) to the carrier layer (2) at least one bonding and / or wrapping process takes place using at least one adhesive material and / or an adhesive. [19] Manufacturing process according to any one of claims 11 to 18, characterized by , that the method also includes a step of positioning and fixing a protective layer (4) on at least a portion of the outer surface (31) of the coating layer (3), i.e. opposite the surface of the coating layer (3) which is positioned opposite the carrier layer (2).