METHOD FOR PRODUCING A VEHICLE INTERIOR TRIM PART AND INTERIOR TRIM PART

Description

[0001] The present invention relates to a method of manufacturing a vehicle interior trim element. The invention also relates to a vehicle interior trim element.

[0002] The invention applies for example to an interior trim element forming a central console, a door panel or a dashboard trim of a vehicle or other types of trim elements.

[0003] Such a trim element may comprise a decorative part and a human-machine interface part defining a human-machine interface provided with one or more interaction zones, such as for example touch interfaces or buttons for controlling vehicle functions.

[0004] It is known to manufacture each of these two parts, for example by molding, independently of one another and then to assemble them, in order to form the filling element.

[0005] However, such a manufacturing process is not entirely satisfactory.

[0006] Indeed, after assembling the two parts of the trim element, their front surfaces are generally not joined and a gap is observed between the adjacent edges of the two parts.

[0007] This gap creates a discontinuity in the design of the trim element. Such a trim element therefore has an unsatisfactory external appearance.

[0008] Furthermore, such discontinuity also affects the quality of the packing element.

[0009] Furthermore, such a manufacturing process comprising at least two molding stages and one assembly stage is uneconomical, particularly due to a significant investment in production machinery and a large number of stages.

[0010] DE 10 2019 008780 describes a method for manufacturing a functional decorative element.

[0011] One of the aims of the invention is to propose a method for manufacturing an interior trim element comprising two parts making it possible to produce a trim element having a satisfactory external appearance and satisfactory quality, while being economical to manufacture.

[0012] Thus, the subject of the invention is a method of manufacturing an interior vehicle trim element according to claim 1.

[0013] Overmolding such a coating layer covering the junction between the front surfaces of the first part and the second part gives the illusion of continuity between the two parts of the trim element, which gives it a satisfactory external appearance. In addition, such a coating layer also has a protective function for the front surface of the two parts, which increases the quality of the trim element.

[0014] Optional features are defined in claims 2 to 7.

[0015] The invention also relates to a vehicle interior trim element according to claim 8.

[0016] Optional features are defined in claims 9 to 12.

[0017] The invention will be better understood on reading the following description, given by way of example and with reference to the appended drawings, among which: there figure 1 is a schematic view of an interior trim element according to the invention; and the figure 2 is a sectional view of the interior trim element of the figure 1 , the section being carried out according to the plane P on the figure 1 .

[0018] There figure 1 illustrates a vehicle interior trim element 10 schematically. The proportions are not respected.

[0019] The trim element 10 is intended to be installed in the passenger compartment of a vehicle, in particular a motor vehicle.

[0020] The trim element 10 is, for example, a vehicle center console intended to be arranged between two seats of a row of seats of the vehicle, for example two front seats. Alternatively, the trim element 10 is, for example, a dashboard, an armrest or a door panel.

[0021] As illustrated in the figure 2 , the filling element 10 comprises a first part 12, a second part 14 and a coating layer 16.

[0022] The first part 12 defines, for example, a human-machine interface provided with one or more interaction zones 18.

[0023] The interaction zones 18 are, for example, touch interfaces or control buttons. Each interaction zone 18 allows a vehicle passenger to control vehicle functions, such as the volume of the car radio, for example.

[0024] The first portion 12 comprises a front surface 20, which is preferably oriented towards the interior of the vehicle passenger compartment and easily accessible by passengers.

[0025] The front surface 20 of the first part 12 thus advantageously defines the exterior visible surface of the first part 12.

[0026] Preferably, the interaction zones 18 are defined on the front surface 20 of the first part 12 of the trim element 10.

[0027] Advantageously, the front surface 20 of the first part 12 is at least partially covered with a decorative film 22.

[0028] As illustrated in the figure 1 , the decorative film 22 allows, for example, the arrangement of a logo or a pictogram on each interaction zone 18, in order to give an indication to passengers on the functionality controlled by said interaction zone 18.

[0029] Such a decorative film 22 is for example a film made of polypropylene, polystyrene, polycarbonate (PC), polyethylene terephthalate (PET) or polymethyl methacrylate (PMMA).

[0030] The film 22 advantageously comprises pigments giving the desired color to the front surface 20 of the first part 12.

[0031] Alternatively, the film 22 is transparent or translucent and inks are printed on at least one of the faces of the film 22, in order to give the desired appearance to the front surface 20 of the first part 12.

[0032] According to a particular embodiment of the invention, functional inks are printed on at least one of the faces of the film 22, and more particularly on the rear face of the film 22. The functional inks used are, for example, conductive inks, in particular silver-based inks, in order to form on the film 22 electrical tracks connected to electronic components, such as light sources for example, or to form electrical capacitances, for example to provide a touch sensor function to the film 22.

[0033] The film 22 has, for example, a thickness of between 100 µm and 1000 µm.

[0034] The first part 12 is made of a first material, and preferably by molding said first material on the back of the decorative film 22, as will be described later.

[0035] The first material is for example chosen from polycarbonate, acrylonitrile butadiene styrene, polyamide, polypropylene, polyethylene, PMMA and their potential combinations.

[0036] The second part 14 of the trim element 10 defines, for example, a structural and decorative part of the trim element 10.

[0037] The second part 14, for example, gives its general shape to the filling element 10.

[0038] The second part 14 advantageously defines structural elements of the trim element 10, such as a cup holder for example in the case where the trim element 10 is a central console.

[0039] The second part 14 comprises a front surface 24, preferably oriented towards the interior of the vehicle interior and defining the exterior visible surface of the second part 14.

[0040] The front surface 24 has, for example, a shiny exterior appearance, giving an enhancing appearance to the trim element 10.

[0041] The second part 14 is adjacent and joined to the first part 12.

[0042] In other words, the play between the two parts 12, 14 is substantially zero, at the junction 26 between the two parts 12, 14.

[0043] Preferably, the front surface 24 of the second part 14 is adjacent and contiguous with the front surface 20 of the first part 12.

[0044] In other words, the front surface 24 of the second part 14 is substantially aligned with the front surface 20 of the first part 12. The front surface 20 of the first part 12 and the front surface 24 of the second part 14 extend continuously at the junction 26.

[0045] Alternatively, the front surface 20 of the first part 12 and the front surface 24 of the second part 14 are not aligned at the junction 26, but are offset in height, for example by a height of less than 1 mm.

[0046] As illustrated in the figure 1 , the front surface 24 of the second part 14 for example completely surrounds the front surface 20 of the first part 12.

[0047] The junction 26 between the two parts 12, 14 is, in this case, defined at the level of the outer periphery of the front surface 20 of the first part 12.

[0048] The second part 14 is made of a second material, and preferably by molding said second material as will be described later.

[0049] The second material is for example identical to the first material.

[0050] In a particular embodiment of the invention, the second material is different from the first material.

[0051] The second material is for example chosen from polycarbonate, acrylonitrile butadiene styrene, polyamide, polypropylene, polyethylene, PMMA and their potential combinations.

[0052] The coating layer 16 is arranged opposite the front surfaces 20, 24 of the first part 12 and the second part 14 of the trim element 10, and preferably completely covers the two front surfaces 20, 24.

[0053] In particular, the coating layer 16 covers the junction 26 between the two parts 12, 14.

[0054] The coating layer 16 advantageously extends uniformly above two front surfaces 20, 24 of the two parts 12, 14, giving an illusion of continuity between said front surfaces 20, 24.

[0055] The coating layer 16 defines an inner surface 28 and an outer surface 30.

[0056] As illustrated in the figure 2 , the inner surface 28 of the coating layer 16 faces the front surface 24 of the second part 14, as well as the front surface 20 of the first part 12. Here it is in contact with the decorative film 22 covering the front surface 20 of the first part 12.

[0057] The outer surface 30 faces away from the first part 12 and the second part 14. It defines, for example, the outer surface of the trim element 10.

[0058] The coating layer 16 is preferably transparent, in order to leave the front surfaces 20, 24 of the first and second parts 12, 14 visible.

[0059] In an exemplary embodiment, the coating layer 16 comprises relief patterns 32 on its outer surface 30.

[0060] The relief patterns 32 can have any suitable shape.

[0061] The relief patterns 32 form, for example, uniformly distributed bands extending opposite at least a portion of the front surface 24 of the second part 14.

[0062] The relief patterns 32 are alternately circular in shape and together define a pattern opposite the second part 14.

[0063] The relief patterns 32 can also define in relief the logos or pictograms defined by the decorative film 22 of the first part 12.

[0064] The relief patterns 32 have, for example, a height of between 0.1 mm and 1 mm.

[0065] Such relief patterns 32 improve the external aesthetic appearance of the trim element and can, for example, provide a particular external aesthetic appearance to the trim element, such as a matte appearance for example.

[0066] The coating layer 16 is made of a coating material. It is preferably obtained by overmolding the coating material onto the front surfaces 20, 24 of the first part 12 and the second part 14 previously molded.

[0067] The coating material is, for example, polyurethane, and in particular polyurethane acrylate (PUA).

[0068] A polyurethane coating material offers the advantage of facilitating the formation of relief patterns 32 directly during the molding step.

[0069] The coating layer 16 has a thickness of between 0.3 mm and 3 mm, and preferably between 0.6 mm and 1 mm.

[0070] A method of manufacturing such a packing element 10 will now be described.

[0071] The manufacturing method comprises a first step of molding the first part 12 of the trim element 10.

[0072] When the first part 12 is provided with a decorative film 22, the first molding step comprises molding the first material on the back of the decorative film 22, so that the decorative film 22 covers the front surface 20 of the first part 12.

[0073] Preferably, the first molding step is, for example, an injection molding step.

[0074] For this purpose, the first material is preferably a thermoplastic material and is more particularly chosen from polycarbonate, acrylonitrile butadiene styrene, polyamide, polypropylene, polyethylene, PMMA and their potential combinations.

[0075] The decorative film 22 is arranged in a first molding cavity, and more particularly only on one of the surfaces of the first molding cavity.

[0076] The first material is then injected into said first molding cavity, preferably in molten form, and comes into contact with the decorative film 22, and in particular with the back of the decorative film 22.

[0077] Upon cooling, the first molding material solidifies in the first molding cavity, thereby forming the first part 12. Optionally, the decorative film 22 is adhered to the first material and thus covers the front surface 20 of the first part 12.

[0078] The manufacturing method comprises a second step of molding the second part 14 of the trim element 10.

[0079] Preferably, the second molding step is also an injection molding step.

[0080] For this purpose, the second material is preferably a thermoplastic material and is more particularly chosen from polycarbonate, acrylonitrile butadiene styrene, polyamide, polypropylene, polyethylene, PMMA and their potential combinations.

[0081] The second material is injected into a second molding cavity, preferably in molten form, and when solidified forms the second part 14 of the trim element 10.

[0082] Preferably, the first molding cavity of the first part 12 and the second molding cavity of the second part 14 are defined in the same mold.

[0083] Advantageously, the second molding step is carried out by overmolding the second part 14 onto the first part 12 previously molded.

[0084] For this purpose, after the first molding step, the first part 12 of the trim element 10 is left in position in the mold and defines a part of the second molding cavity into which the second material is injected so as to form the second part 14 of the trim element 10.

[0085] Alternatively, the first molding step is carried out by overmolding the first part 12 onto the second part 14 previously molded.

[0086] After the first and second molding steps carried out successively, the first part 12 and the second part 14 are adjacent and joined.

[0087] Preferably, the front surface 20 of the first part 12 and the front surface 24 of the second part 14 are adjacent and contiguous.

[0088] Advantageously, the overmolding of one of the parts on the other makes it possible to produce the front surfaces 20, 24 of the two parts 12, 14 adjoining, i.e. having between them a substantially zero clearance.

[0089] Alternatively, the front surface 20 of the first part 12 and the front surface 24 of the second part 14 are offset in height, for example by a height of less than 1 mm.

[0090] The manufacturing method then comprises a step of overmolding the coating layer 16 by molding the coating material opposite the front surfaces 20, 24 of the first part 12 and the second part 14, and more particularly covering the junction 26 between the two parts 12, 14.

[0091] Preferably, this overmolding step is a step of injection molding the coating material onto the front surfaces 20, 24 of the first part 12 and the second part 14, more particularly in a third molding cavity.

[0092] The third molding cavity is advantageously made in the same mold as the first and second molding cavities.

[0093] In the preferred embodiment of the invention in which the coating material is a polyurethane, two components, in particular a pre-polymer, such as polyol for example, and a catalyst agent, such as isocynate for example, are for example injected into the third molding cavity in liquid form, then solidify by crosslinking, thus forming the coating layer 16.

[0094] Preferably, the overmolding step comprises forming the relief patterns 32 on the outer surface 30 of the coating layer 16.

[0095] For this purpose, the imprint of each relief pattern 32 is preferably formed in the third molding cavity.

[0096] The components injected in liquid form are housed in the imprints of the relief patterns 32 defined in the third molding cavity, thus forming, after crosslinking, the relief patterns 32 on the outer surface 30 of the coating layer 16.

[0097] Optionally, the manufacturing method also comprises a step of milling the trim element 10, in particular with the aim of improving the aesthetic appearance of the trim element 10.

[0098] By milling step, we mean a removal of material by rotation of a cutting tool and the advancement of the part, here the trim element 10.

[0099] Preferably, said milling step is carried out with the aim of removing material from the periphery of the trim element 10, and in particular of removing the first material from the first part 12 and / or the second material from the second part 14 forming the periphery of the trim element 10 and which has not been covered with coating material 16.

[0100] Such a trim element 10 thus manufactured comprises for example a part defining a man-machine interface and a decorative part and has a satisfactory external appearance.

[0101] Indeed, the coating layer 16, in particular covering the junction 26 between the two parts 12, 14, makes it possible to give an illusion of continuity between the two parts.

[0102] The formation of relief patterns 32 on the coating layer 16 also improves the external appearance.

[0103] In addition, due to its composition, in particular polyurethane, the coating layer 16 protects the front surfaces 20, 24 of the two parts 12, 14, in particular from aging and yellowing.

[0104] Furthermore, the fact that the front surfaces 20, 24 are joined also improves the strength of the trim element 10.

[0105] In addition, such a manufacturing method reduces the number of process steps, such as, for example, the assembly and painting steps. Indeed, the coating layer 16 gives a satisfactory appearance to the trim element 10, for example bringing out the desired glossy appearance of the second part 14, and protects the front surfaces 20, 24. A painting step is thus not necessary.

[0106] Furthermore, since all three casting steps can be carried out in the same mold, such a manufacturing process is also economical and requires little machine investment.

Claims

1. Method for manufacturing a vehicle interior trim element (10), the manufacturing method comprising: - a first step of molding a first portion (12) of the trim element (10) by molding a first molding material, the first portion (12) comprising a front surface (20), - a second step of molding a second portion (14) of the trim element (10) by molding a second molding material, the second portion (14) comprising a front surface (24), and - a step of overmolding a coating layer (16) by molding a coating material facing the front surfaces (20, 24) of the previously molded first portion (12) and the second portion (14), the first portion (12) and the second portion (14) being adjacent and contiguous, the coating layer (16) covering the junction (26) between the first portion (12) and the second portion (14), characterized in that the first portion (12) defines a man-machine interface provided with one or more interaction zones (18).

2. Manufacturing method according to claim 1, wherein the coating material is polyurethane.

3. Manufacturing method according to claim 1 or 2, wherein the first molding step comprises molding the first material on the back of a decorative film (22) such that the decorative film (22) covers the front surface (20) of the first portion (12).

4. Manufacturing method according to any of the preceding claims, wherein the second molding step is performed by overmolding the second portion (14) onto the previously molded first portion (12) or the first molding step is performed by overmolding the first portion (12) onto the previously molded second portion (14).

5. Manufacturing method according to claim 4, wherein a first mold cavity of the first portion (12) and a second mold cavity of the second portion (14) are defined in the same mold.

6. Manufacturing method according to any of the preceding claims, wherein the first molding material and / or the second molding material is selected from polycarbonate, acrylonitrile butadiene styrene, polyamide, polypropylene, polyethylene, PMMA and potential combinations thereof.

7. Manufacturing method according to any of the preceding claims, wherein the step of overmolding the coating layer (16) comprises forming raised patterns (32) on an outer surface (30) of the coating layer (16) facing away from the first portion (12) and the second portion (14).

8. Interior trim element for a vehicle, the interior trim element (10) comprising: - a first portion (12) made of a first material and comprising a front surface (20), - a second portion (14) made of a second material, comprising a front surface (24), and being adjacent to and contiguous with the first portion (12), and - a coating layer (16) facing the front surfaces (20, 24) of the first portion (12) and the second portion (14) of the trim element (10), the coating layer (16) covering the junction (26) between the first portion (12) and the second portion (14), characterized in that the first portion (12) defines a man-machine interface provided with one or more interaction zones (18).

9. Interior trim element for a vehicle according to claim 8, wherein the coating layer (16) comprises raised patterns (32) on an outer surface (30) of the coating layer (16) facing away from the first portion (12) and the second portion (14).

10. Trim element according to claim 8 or 9, wherein the coating material is polyurethane.

11. Trim element according to any of claims 8 to 10, wherein the front surface of the first portion (12) is at least partially covered with a decorative film.

12. Trim element according to any of claims 8 to 11, wherein the first molding material and / or the second molding material is selected from polycarbonate, acrylonitrile butadiene styrene, polyamide, polypropylene, polyethylene, PMMA and potential combinations thereof.