VEHICLE INTERIOR TRIM PART AND METHOD FOR ITS PRODUCTION

Description

[0001] The present invention relates to the field of interior equipment in vehicles, in particular interior trim parts. It relates to a vehicle interior trim part and its manufacturing method.

[0002] Trim (or covering) parts include, but are not limited to, dashboards, door panels, central console panels, window pillars, and similar cabinetwork parts.

[0003] Among the trim pieces, some integrate, by extending into the body of the latter, functional elements ensuring specific functions such as, for example, heating, lighting, detection, measurement, reception, transmission. To enable their activation or operation, these functional elements generally require a connection to a source of electrical energy or to an electronic device itself powered or comprising a source of electrical energy. Such an electronic device makes it possible to supply energy and / or transmit information to the functional element and / or to process the information / data generated and emitted by the functional element.

[0004] Trim parts incorporating such functions thus provide useful services to vehicle users (drivers and / or passengers) and improve their comfort.

[0005] Such a trim piece has a visible (or exposed) face visible to the occupants of the vehicle and a fine surface structure. The trim piece comprises a non-visible support layer, a covering (or decorative) layer comprising said visible face and at least one functional element located between the support layer and the covering layer. The or each functional element thus interposed (or sandwiched) between said support and covering layers extends over all or part of their surfaces while being in contact with the latter. In the case where several functional elements are provided, each functional element forms, according to its surface area, a functional point or surface.

[0006] The functional element is integrated into the trim piece during its manufacture and is interposed between the support and trim layers, being positioned as close as possible to the exposed face in order to provide the most effective interaction properties with the vehicle interior and its occupants. Furthermore, the functional element is positioned so that it can be easily connected to a power source or an electrical / electronic device when installing the trim piece in the vehicle.

[0007] Document FR3074567 discloses such a trim piece with the subject matter being a three-layer radiant panel intended to be placed inside a vehicle passenger compartment, for example a motor vehicle, and fulfilling a heating function. For this purpose, it comprises at least three stacked layers, each of which may comprise a plurality of sub-layers and / or sheets. The second layer is thin and generates radiation and for this purpose comprises at least one heating element and at least two electrodes for powering the latter. The heating element comprises in particular a layer of acrylic paint comprising carbon particles and / or metal particles which emit heat under the effect of the electrical power supplied to the heating element by two electrodes connected to the layer of paint.The third layer is oriented toward the passenger compartment (more specifically toward a vehicle user) and forms a trim layer providing an aesthetic appearance to the panel in the passenger compartment. The first layer is only in contact with the second layer and the third layer is only in contact with the second layer. Alternatively, the first layer is in contact with the third layer around the perimeter of the second layer.

[0008] However, a trim piece such as that disclosed in document FR3074567 has several drawbacks. First of all, it does not allow a heating element to be positioned locally, i.e. at a precise point relative to the surface of the trim piece, since the heating element is constituted by a layer of paint containing a plurality of heating particles. On the other hand, the cost is high due to the plurality of particles embedded or embedded in the material and over the entire surface of the second layer spread between the first and third layers.Furthermore, such a trim piece, like other pieces such as those disclosed in document DE102015220253, use at least two specific and separate connection pieces which generate a structural and mechanical discontinuity in this layer and the connection, for example of the electrodes to the paint layer, generates losses impacting the energy efficiency. Document FR3116474A1 discloses a trim piece according to the preamble of claim 1.

[0009] The present invention aims to overcome these drawbacks.

[0010] To this end, the present invention relates to an interior trim piece for a vehicle, said trim piece having a three-dimensional shape and comprising, on the one hand, a multi-layer structure comprising a support layer having two opposite faces, namely an external face and an internal face and an added covering layer and having two opposite faces, namely an external face defining a visible face of the trim piece and an internal face facing the internal face of the support layer and, on the other hand, at least one functional element, preferably of thin thickness, comprising a functional surface extension part arranged between the support layer and the covering layer, the multi-layer structure further comprising a connecting layer interposed between the support layer and the covering layer while being fixed on the internal faces of the latter so as to assemble / connect them together,at least the functional part of the or at least one of the functional element(s) being arranged and maintained locally between the covering layer and the support layer while being located outside the connecting layer, characterized in that the functional part is extended continuously by an elongated connection or joining part allowing its electrical supply and / or the transmission of electrical signals and in that the elongated connection or joining part of the or at least one of the functional element(s) passes through the thickness of the support layer beyond its external face while being embedded in or coated by the support layer.,

[0011] The present invention also relates to a method for producing an interior trim piece for a vehicle, said trim piece having a three-dimensional shape and comprising, on the one hand, a multi-layer structure comprising a support layer having two opposite faces, namely an external face and an internal face and an added covering layer and having two opposite faces, namely an external face defining a visible face of the trim piece and an internal face facing the internal face of the support layer and, on the other hand, at least one functional element, preferably of thin thickness, comprising a functional surface extension part arranged between the support layer and the covering layer and extending continuously by an elongated connection or joining part allowing its electrical supply and / or the transmission of electrical signals,the multi-layer structure further comprising a bonding layer interposed between the support layer and the covering layer, being fixed on the internal faces of the latter so as to assemble / bond them together, at least the functional part of the or at least one of the functional element(s) being arranged and held locally between the covering layer and the support layer, being located outside the bonding layer, characterized in that it consists of carrying out the following steps, using an injection mold comprising two parts movable relative to each other, namely a first part provided with means for injecting a material intended to form the support layer and a second part making it possible to close the mold: , providing at least one functional element, placing the or each functional element in the mold while maintaining it in a predetermined position in the first part of the mold, closing the mold so as to form an injection chamber and injecting into the latter a material intended to form the support layer so as to fix at least the functional part of the or each functional element on the surface of the support layer intended to form its internal face in the trim part, opening the mold to demold and extract the support layer provided with the functional element(s), with the elongated connecting or joining part(s) passing through the material of the support layer,providing a covering layer and fixing it to the support layer by means of a bonding layer such that the covering layer covers at least the functional part of the functional element(s) and at least the functional part of the or at least one of the functional element(s) is located outside the area occupied by the bonding layer.

[0012] Such a method according to the present invention is characterized in that it consists of carrying out the following steps, using an injection mold comprising two parts which can move relative to each other, namely a first part provided with means for injecting a material intended to form the support layer and a second part making it possible to close the mold: providing at least one functional element, placing the or each functional element in the mold while maintaining it in a predetermined position in the first part of the mold, closing the mold so as to form an injection chamber and injecting into the latter a material intended to form the support layer so as to fix at least the functional part of the or each functional element on the surface of the support layer intended to form its internal face in the trim part, opening the mold to demold and extract the support layer provided with the functional element(s), possibly with the elongated connecting or joining part(s) passing through the material of the support layer,providing a covering layer and fixing it to the support layer by means of a bonding layer such that the covering layer covers at least the functional part of the functional element(s) and at least the functional part of the or at least one of the functional element(s) is located outside the bonding layer.

[0013] The invention will be better understood from the following description, which relates to a preferred embodiment, given as a non-limiting example, and explained with reference to the appended schematic drawings, in which: [ Fig. 1 ] represents a sectional view of a trim piece according to the present invention, in one embodiment of the covering layer completely covering the support layer, [ Fig. 2 ] is a sectional view of a piece of upholstery according to the present invention, in one embodiment of the covering layer comprising a comfort layer and completely covering the support layer, [ Fig. 3 ] is a sectional view of a trim piece according to the present invention, in an embodiment where the covering layer partially covers the support layer, [ Fig. 4 ] is a sectional view of a trim piece according to the present invention, according to a particular embodiment of the piece shown in the figure 3 , [ Fig. 5 ] is a sectional view of a trim piece according to the present invention, in a particular embodiment of the support layer, [ Fig. 6 ] is a top view of a functional element, [ Fig. 7 ] is a sectional view of the functional element shown in the figure 6 , [ Fig. 8 ] is a sectional view of an injection mold that can be used to implement the method according to the present invention, [ Fig. 9 ], [ Fig. 10 ], [ Fig. 11 ], [ Fig. 12 ], [ Fig. 13 ] show the mold shown on the figure 8 when used in the various stages of the process preceding the stage of fixing the covering layer to the support layer by the bonding layer, known as the last stage, [ Fig. 14 ] illustrates the last step of the process.

[0014] THE figures 1 à 7 show an interior trim piece, according to the present invention, for a vehicle, said trim piece having a three-dimensional shape and comprising: a multi-layer structure comprising a support layer 1 having two opposite faces, namely an external face 1a and an internal face 1b and a covering layer 2 added and having two opposite faces, namely an external face 2a defining a visible face of the trim piece and an internal face 2b facing the internal face 1b of the support layer 1, and at least one functional element 3, preferably of thin thickness, comprising a functional part 3a of surface extension arranged between the support layer 1 and the covering layer 2.

[0015] The functional part 3 is extended continuously (i.e. without electrical discontinuity due, for example, to an electrical connection or connection) by an elongated connection or connection part 3b allowing its electrical supply and / or the transmission of electrical signals.

[0016] Such a trim (or dressing) part may include, in particular, but not limited to, dashboards, door panels, central console panels, window pillars, and similar cabinet parts.

[0017] This continuous extension of the functional part 3 makes it possible to avoid a structural and mechanical discontinuity in this layer and the connection, for example, of other elements, such as electrodes generating losses impacting the energy efficiency and increasing the cost price of the trim part.

[0018] In such a trim piece, the multi-layer structure further comprises (or includes) a connecting layer 4 interposed between the support layer 1 and the covering layer 2, being fixed to the internal faces 1b, 2b of the latter so as to assemble (or connect) them together.

[0019] More particularly, it is understood that the bonding layer 4 interposed between the support layer 1 and the covering layer 2 is fixed solidly or robustly on the internal faces 1b, 2b of the latter so as to assemble them (or bond them) together in order to be able to comply with the specifications and the usage stresses.

[0020] An added layer is understood to mean a layer which is not produced during manufacturing with the support layer 1, for example in a mold by injection of plastic material and overmolding.

[0021] The interposed bonding layer 4 may extend continuously or discontinuously. In the case where it is discontinuous, it is understood that the bonding layer 4 comprises at least two bonding layer parts separated from each other between the support layer 1 and the covering layer 2. Such a characteristic makes it possible to ensure the fixing of the support layer 1 with the covering layer 2 while limiting the surface area and the quantity of bonding layer 4 used. This embodiment is not illustrated by the accompanying drawings.

[0022] The or each functional element 3 can provide specific functions such as, for example, heating, lighting, detection, measurement, reception, transmission. To enable their activation or operation, the functional element 3 can be connected, via its elongated connection or linking part 3b, to a source of electrical energy or to an electronic device itself powered or comprising a source of electrical energy. Such an electronic device makes it possible to supply energy and / or transmit information to the functional element and / or to process the information / data generated and emitted by the functional element 3.

[0023] At least the functional part 3a of the or at least one of the functional element(s) 3 is arranged and held locally between the covering layer 2 and the support layer 1 while being located outside the connecting layer 4. This characteristic makes it possible to arrange locally, independently of the other layers, at one or more specific points on the surface or volume of the trim part, one or more functional element(s) 3. “Outside” means an arrangement where (at least) the functional part 3a of the or at least one of the functional element(s) 3 is not located, or does not extend, in or inside the connecting layer 4, that is to say in the material, or the thickness of material, of the connecting layer 4, but is located, or extends, entirely or in its major part, outside the connecting layer 4.

[0024] Cover layer 2 can completely cover ( figure 1 ) or partially ( figures 3 et 4 ) the support layer 1. In the case of a partial covering, the respective visible or exposed surfaces of the two layers 1, 2 then form the visible face 2a, 1b of the trim piece. It is then understood that a part (not covered by the covering layer 2) of the internal face 1b of the support layer 1 then forms, with the external face 2a of the covering layer 2, a part of the visible (or visible) face of the trim piece. In this case there may be an offset between these surfaces at the level of the visible face 2a, 1b, with a misalignment d, also due to the presence of the bonding layer 4 interposed between the two layers 1, 2 and adding a thickness. In this case of partial covering, the visible face 2a of the covering layer 2 may be in positive elevation ( figures 3 et 4 ) or negative or at the same level relative to the visible face (or appearance surface) of the support layer 1. In the case of a negative difference in level (not shown in the attached figures), the internal face 1b of the support layer 1 may comprise a housing (or a hollow) receiving the covering layer 2 in its entire thickness. Such a housing may also be provided with a positive difference in level, in this case only part of the thickness of the covering layer 2 extends into the housing and the other part outside.

[0025] In a variant of the case where the covering layer 2 partially covers the support layer 1, as can be seen in the figure 4 , the periphery of the covering layer 2 can be materialized in the support layer 1 by an arrangement, or a geometric characteristic, 1c linear in the form of a hollow, for example of the groove type, made in the internal face 1a of the support layer 1 and receiving at least the peripheral edge of the covering layer 2. Thus, this arrangement or geometric characteristic 1c follows a path on the periphery of the covering layer 3 by delimiting the area of ​​the surface of the support layer 1 covered by the covering layer 3.

[0026] If we now refer, in particular, to the figures 6 And 7, it can be seen that the functional part 3a can comprise a surface extension support part 30a carrying or integrating at least one electrical or electronic component 31a performing the intended function (see above the functions which can for example be provided) when it is activated or electrically powered. The connection or joining part 3b, preferably of elongated shape, can comprise a support part 30b carrying or integrating one or more conductive power or transmission lines or strips 31b and an end (or terminal) connection part 32b for its electrical connection.

[0027] Preferably, one can see on the figure 5 that the present invention may provide that the support layer 1 has a honeycomb structure integrating, for example, encapsulated air bubbles 1d making it possible to obtain a thermal conductivity of the support layer 1 lower than that of the covering layer 2. It is thus possible to obtain thermal insulation in the direction of the external face 1a of the support layer 1 and better diffusion of the heat or thermal radiation generated towards the covering layer (2), and therefore towards the visible face 2a and the internal space of the vehicle. Such a characteristic is more particularly interesting when the functional element 3 performs a heating function.

[0028] Preferably, the bonding layer 4 is made from an adhesive or glue, for example of the polyurethane, acrylic or polypropylene type.

[0029] Preferably, the support layer 1 is a layer of injected material, preferably of injected plastic material, for example of the polypropylene type.

[0030] Preferably, at least the functional part 3a of the or at least one of the functional element(s) 3 can be in direct surface contact: either with the internal faces 1b, 2b of the support 1 and covering 2 layers (shape not illustrated by the attached figures), or, such as the shape illustrated in the figures 1 à 5 , with the internal face 1b of the support layer 1 and the bonding layer 4, or with the internal face 2b of the covering layer 2 and the bonding layer 4 (shape not illustrated by the attached figures).

[0031] In a preferred embodiment illustrated in the figure 2 , the covering layer 2 may comprise a first layer, called the decorative layer 2c, comprising the visible face 2a and a second layer, called the comfort layer 2d, comprising the internal face 2b. The term "comfort layer 2d" is understood to mean a layer whose material(s) constituting it give it a flexible, easily deformable or compressible consistency. Thus, the covering layer 2, which could comprise at least one other layer between the first and second layers 2c, 2d, allows the user (occupant of the vehicle) to have comfort of touch when pressing on the visible face 2a, in particular in a direction D substantially perpendicular to it due to the comfort layer 2d. Preferably, the comfort layer 2d may be made from a foam, preferably a synthetic foam, preferably of the polyurethane, polyethylene or polypropylene type.

[0032] The connection or joining part 3b of the or at least one of the functional element(s) 3 passes through the thickness of the support layer 1 beyond its external face 1a by being embedded (or embedded) in or coated by the support layer 1.

[0033] Preferably, the covering layer 2 can be made from at least one element chosen from the group of elements comprising a synthetic or natural skin, a film, a layer of synthetic, metallic or natural material or a textile.

[0034] The present invention also relates to a method for producing an interior trim part for a vehicle, said trim part being able to be a trim part as described previously. More particularly, in such a trim part the functional part 3a of the or at least one of the functional element(s) 3 is in direct surface contact with the internal face 1b of the support layer 1 and either with the connecting layer 4 or with the covering layer 2.

[0035] According to the present invention, the method is characterized in that it consists of carrying out the following steps, using an injection mold M comprising two parts M1, M2 movable relative to each other, namely a first part M1 provided with injection means M10 of a material intended to form the support layer 1 and a second part M2 making it possible to close the mold M: (i) provide at least one functional element 3 ( figure 9 ), ii) placing the or each functional element 3 in the mold M while maintaining it in a predetermined position in the first part M1 of the mold M ( figure 10 ), iii) close the mold M, that is to say by bringing together and mutual contact of the two moving parts M1, M2, so as to form an injection chamber M3 ( figure 11 ) and injecting into the latter a material intended to form the support layer 1 so as to fix at least the functional part 3a of the or each functional element 3 on the surface of the support layer 1 intended to form its internal face 1b in the trim part ( figures 12 ), iv) opening the mold to demold and extract the support layer 1 provided with the functional element(s) 3, with the elongated connecting or joining part 3b passing through the material of the support layer 1 ( figure 13 ), v) providing a covering layer 2 and fixing the latter on the support layer 1 by means of a bonding layer 4 so that the covering layer 2 covers at least the functional part 3a of the functional element(s) 3 and that at least the functional part 3a of the or at least one of the functional element(s) 3 is located outside the bonding layer 4 ( figure 14 ).

[0036] Preferably, the bonding layer 4 may be a glue or an adhesive. The glue or adhesive, or other material capable of providing the bond and being spread, may be applied to the support layer 1 and / or to the covering layer 2, and possibly to the functional part 3a of the or at least one of the functional element(s) 3: by spreading, for example using a brush or roller, or by spraying, for example using a gun.

[0037] Spreading the glue or adhesive can be done manually or (automatically) using a robot.

[0038] The first part M1 of the mold M may comprise a punch M11 in which the sealed cavity M110 can be made. Such a mold is described for example in document FR2200727.

[0039] Preferably, in step ii), the method may consist of placing the or each functional element 3 in the mold M while maintaining it in a predetermined position in the first part M1 of the mold M in such a way that at least one end portion 33b of the elongated connection or joining part 3b is housed in a sealed cavity M110 of the first part M1 of the mold, more particularly of the punch M11. Thus, in step iii) of closing the mold M, the or their elongated connection or joining part 3b may, in a preferred embodiment, be embedded or embedded in the support layer 1 and pass through it with the exception of a part comprising at least the end portion 32b.At least the end portion 32b then protrudes from the support layer 1, in particular from its external face 1a, to the outside, in order to easily allow its connection or its connection with external means allowing its electrical supply and / or the transmission of electrical signals.

[0040] Of course, the invention is not limited to the embodiment described and shown in the attached drawings. Modifications remain possible, in particular from the point of view of the constitution of the various elements or by substitution of technical equivalents, without departing from the scope of protection of the invention, which is defined by the attached claims.

Claims

1. Inner trim component for a vehicle, said trim component having a three-dimensional shape and comprising, on the one hand, a multilayer structure having a support layer (1) that has two opposite faces, namely an external face (1a) and an internal face (1b), and an added cladding layer (2) that has two opposite faces, namely an external face (2a) defining a visible face of the trim component and an internal face (2b) turned towards the internal face (1b) of the support layer (1), and, on the other hand, at least one functional element (3), preferably of small thickness, comprising a functional part (3a) of surface extension that is disposed between the support layer (1) and the cladding layer (2), the multilayer structure also having a connecting layer (4) interposed between the support layer (1) and the cladding layer (2), being fastened to the internal faces (1b, 2b) of the latter so as to join / connect them to each other, at least the functional part (3a) of the or of at least one of the functional element(s) (3) being disposed and held locally between the cladding layer (2) and the support layer (1), being situated outside the connecting layer (4), characterized in that the functional part (3a) is extended continuously by an elongate connection or linking part (3b) allowing the electrical supply thereof and / or the transmission of electrical signals, and in that the elongate connection or linking part (3b) of the or of at least one of the functional element(s) (3) passes through the thickness of the support layer (1) beyond the external face (1a) thereof, being embedded in or coated by the support layer (1).

2. Trim component according to Claim 1, characterized in that the connecting layer (4) is made from an adhesive or a glue.

3. Trim component according to Claim 1 or 2, characterized in that the support layer (1) is a layer of injected material, preferably of injected plastic material.

4. Trim component according to any one of Claims 1 to 3, characterized in that at least the functional part (3a) of the or of at least one of the functional element (s) (3) is in direct surface contact either with the internal faces (1b, 2b) of the support (1) and cladding (2) layers, or with the internal face (1b) of the support layer (1) and the connecting layer (4), or with the internal face (2b) of the cladding layer (2) and the connecting layer (4).

5. Trim component according to any one of Claims 1 to 4, characterized in that the cladding layer (2) comprises a first layer, referred to as decorative layer (2c), which has the visible face (2a), and a second layer, referred to as comfort layer (2d), which has the internal face (2b).

6. Trim component according to Claim 5, characterized in that the comfort layer (2d) is made from a foam, preferably a synthetic foam, preferentially of polyurethane, polyethylene or polypropylene type.

7. Trim component according to any one of Claims 1 to 6, characterized in that the cladding layer (2) partially covers the support layer (1).

8. Trim component according to Claim 7, characterized in that the periphery of the cladding layer (2) is materialized in the support layer (1) by an arrangement, or a linear geometric feature (1c), in the form of a recess, for example of the groove type, made in the internal face (1a) of the support layer (1) and receiving at least the peripheral edge (2e) of the cladding layer (2).

9. Trim component according to any one of Claims 1 to 8, characterized in that the cladding layer (2) is made from at least one element chosen from the group of elements comprising a synthetic or natural skin, a film, a layer of synthetic, metallic or natural material or a textile.

10. Trim component according to any one of Claims 1 to 9, characterized in that the support layer (1) has a cellular structure incorporating, for example, encapsulated air bubbles (1d) that make it possible to obtain a thermal conductivity of the support layer (1) that is lower than that of the cladding layer (2).

11. Method for producing an inner trim component for a vehicle, said trim component having a three-dimensional shape and comprising, on the one hand, a multilayer structure having a support layer (1) that has two opposite faces, namely an external face (1a) and an internal face (1b), and an added cladding layer (2) that has two opposite faces, namely an external face (2a) defining a visible face of the trim component and an internal face (2b) turned towards the internal face (1b) of the support layer (1), and, on the other hand, at least one functional element (3), preferably of small thickness, comprising a functional part (3a) of surface extension that is disposed between the support layer (1) and the cladding layer (2) and is extended continuously by an elongate connection or linking part (3b) allowing the electrical supply thereof and / or the transmission of electrical signals, the multilayer structure also having a connecting layer (4) interposed between the support layer (1) and the cladding layer (2), being fastened to the internal faces (1b, 2b) of the latter so as to join / connect them to each other, at least the functional part (3a) of the or of at least one of the functional element(s) (3) being disposed and held locally between the cladding layer (2) and the support layer (1), being situated outside the connecting layer (4), which method is characterized in that it consists in carrying out the following steps, using an injection mould (M) comprising two parts (M1, M2) that are able to move relative to one another, namely a first part (M1) provided with means for injecting (M10) a material intended to form the support layer (1) and a second part (M2) that makes it possible to close the mould (M): - providing at least one functional element (3), - putting the or each functional element (3) in place in the mould (M), holding it in a predetermined position in the first part (M1) of the mould (M), - closing the mould (M) so as to form an injection chamber (M3) and to inject into the latter a material intended to form the support layer (1) so as to fasten at least the functional part (3a) of the or of each functional element (3) to the surface of the support layer (1) that is intended to form the internal face (1b) thereof in the trim component, - opening the mould (M) in order to demould and extract the support layer (1) provided with the one or more functional element(s) (3), with the or their elongate connection or linking part (3b) passing through the material of the support layer (1), - providing a cladding layer (2) and fastening it to the support layer (1) by means of a connecting layer (4) such that the cladding layer (2) covers at least the functional part (3a) of the one or more functional elements (3) and that at least the functional part (3a) of the or of at least one of the functional element(s) (3) is situated outside the zone occupied by the connecting layer (4).

12. Method according to Claim 11, characterized in that the connecting layer (4) is a glue or an adhesive applied to the support layer (1) and / or to the cladding layer (2), and optionally to the functional part (3a) of the or of at least one of the functional element (s) (3) by spreading, for example by means of a brush or a roller, or by spraying, for example using a gun or a nozzle.