Process and assembly for manufacturing a part

Abstract

Method and assembly for manufacturing a part The part (1) comprises a support layer (3), a decorative layer (5) and a structural part (7). The method comprises the following steps: - introducing into a mold (9) a support sheet (11) carrying the decorative layer (5); - pinching the support sheet (11) against a first part (13) of the mold by a frame (15); - closing the mold (9), a first surface (27) of the first mold part (13) and a second surface (29) of a second mold part (25) together delimiting a cavity (31); - injecting the support layer (3) into the cavity (31) and transferring the decorative layer (5); - opening the mold (9), the support layer (3) remaining fixed to the first mold part (13) by at least one movable locking member (33) mounted on the frame (15);- closing the mold (9), the first surface (27) of the first mold part (13) and another second surface (35) of another second mold part (37) together delimiting another cavity (39); - moving the at least one locking member (33) relative to the frame (15) to a position for releasing the support layer (3); - injecting the structural part (7) into the other cavity (39) and removing the part (1). Figure for the abstract: 7;

Description

Title of the invention: Method and assembly for manufacturing a part

[0001] The present invention generally relates to an injection method of the IMD (In Mold Decoration) type.

[0002] Such a method may be used for manufacturing a part comprising a support layer, a decorative layer covering a first face of the support layer and a structural part fixed to a second face of the support layer opposite the first face.

[0003] The first face of the support layer is the visible face.

[0004] In this case, it is particularly interesting to use the same mold to inject the support layer and the structural part.

[0005] It is possible to inject the structural part first, the support layer then being injected between the decorative layer and the structural part.

[0006] In this case, defects were observed on the visible face of the part.

[0007] In this context, the invention aims to propose a manufacturing method allowing better control of the quality of the parts produced.

[0008] To this end, the invention relates to a method for manufacturing a part comprising a support layer, a decorative layer covering a first face of the support layer, and a structural part fixed to a second face of the support layer opposite the first face, the method comprising the following steps: - introduction into a mold of a support sheet, the decorative layer being deposited on the support sheet;

[0009] - pinching the support sheet against a first part of the mold by a frame; - closing the mold, a first surface of the first mold part and a second surface of a second mold part together delimiting a cavity, the support sheet being engaged in the cavity opposite the first surface, the decorative layer extending opposite the second surface;

[0010] - injection of the support layer into the cavity between the decorative layer and the second surface, the decorative layer being transferred onto the support layer;

[0011] - opening the mold, the support layer remaining fixed to the first mold part by at least one movable locking member mounted on the frame, the at least one locking member occupying a position relative to the frame for locking the support layer; - closing the mold, the first surface of the first mold part and another second surface of another second mold part together delimiting another cavity, the support layer being engaged in the other cavity opposite the other second surface;

[0012] - moving the at least one locking member relative to the frame to a position release in which the support layer is not secured to the first mold part by the locking member;

[0013] - injection of the structural part into the other cavity between the support layer and the other second surface;

[0014] - opening of the mold and evacuation of the part.

[0015] The manufacturing method of the invention makes it possible to first inject the layer of support, and secondly the structural part.

[0016] This allows for better control of the quality of the part obtained.

[0017] Indeed, the structural part is generally more massive. In the case of a high-speed manufacturing process, if the structural part is injected before the support layer, it does not have time to cool and solidify completely before injection of the support layer.

[0018] As a result, the solidification of the structural part ends after injection of the support layer, and there is a risk of formation of shrinkage on the visible face of the support layer.

[0019] In the method of the invention, because the support layer is injected before the structural part, no shrinkage occurs on the visible face of the support layer.

[0020] Such an organization of the manufacturing process, with injection first of the support layer and then second of the structural part, is made possible by the fact that the frame holds the support sheet against the first mold part.

[0021] The frame incorporates at least one locking member for fixing the support layer to the first mold part after opening the mold. This allows, after the step of injecting the support layer, to put in place the other second mold part, allowing the structural part to be injected.

[0022] The manufacturing process may further have one or more of the following characteristics, considered individually or in all technically possible combinations:

[0023] - the introduction step is performed by moving relative to the first part of molds a continuous film comprising a large number of sheets each bearing a layer of decoration;

[0024] - the decorative layer comprises an ink layer;

[0025] - the or each locking member is movable in translation relative to the frame between the locking position and the release position;

[0026] - the or each locking member is urged towards the locking position by a return member mounted on the frame;

[0027] - the or each locking member is moved into the release position by a cam member mounted on the other second mold part.

[0028] According to a second aspect, the invention relates to an assembly for manufacturing a part comprising a support layer, a decorative layer covering a first face of the support layer and a structural part fixed to a second face of the support layer opposite the first face, the assembly comprising:

[0029] - a mold comprising a first mold part having a first surface and a second mold portion having a second surface, the first and second mold portions being movable relative to each other between a mold open position and a mold closed position, the first surface and the second surface together defining a cavity in the mold closed position;

[0030] - a device for introducing a support sheet into the mold, the layer of decoration being deposited on the support sheet;

[0031] - a device for pinching the sheet against the first part of the mold by a frame, the support sheet being engaged in the cavity opposite the first surface, the decorative layer extending opposite the first surface;

[0032] - a device for injecting the support layer into the cavity between the support layer decor and the second surface, the decor layer being adapted to be transferred onto the support layer during injection;

[0033] - at least one movable locking member mounted on the frame, the at least one member of blocking being movable relative to the frame between a blocking position in which the support layer is fixed to the first mold part by the blocking member and a release position in which the support layer is not fixed to the first mold part by the blocking member;

[0034] - another second mold part having another second surface, the first mold part and the other second mold part being movable relative to each other between another mold opening position and another mold closing position, the first surface and the other second surface together defining another cavity in the other closing position, the support layer being engaged in the other cavity opposite the other second surface in the other closing position;

[0035] - a device for injecting the structural part into the other cavity between the layer support and the other second surface;

[0036] - a device for moving the at least one locking member relative to the frame to the release position.

[0037] The assembly may furthermore have one or more of the following characteristics, considered individually or in all technically possible combinations:

[0038] - the or each locking member is movable in translation relative to the frame between the locking position and the release position;

[0039] - the frame comprises a return member urging the or each blocking member to the blocking position;

[0040] - the movement device comprises for the or each blocking member a cam member mounted on the other second mold part.

[0041] Other characteristics and advantages of the invention will emerge from the detailed description given below, for information purposes only and in no way limiting, with reference to the appended figures 1 to 9 [Fig.1][Fig.2][Fig.3][Fig.4][Fig.5][Fig.6][Fig.7] [Fig.8][Fig.9], these figures showing the successive stages of the manufacturing process.

[0042] The manufacturing method and assembly illustrated in Figures 1 to 9 are intended for the manufacturing of a part 1 comprising, as visible in [Fig.9], a support layer 3, a decorative layer 5 covering a first face of the support layer 3 and a structural part 7 fixed to a second face of the support layer 3 opposite the first face.

[0043] This part is typically a part of the interior of a vehicle, in particular an automobile, for example a part of the passenger compartment of this vehicle.

[0044] For example, the part is a trim part for an opening of the vehicle, or a part of the dashboard, or a part of the central console, or any other part of the passenger compartment.

[0045] The support layer 3 is typically made of a plastic material, for example polycarbonate (PC), polymethyl methacrylate acrylic (PMMA), polypropylene (PP), acrylonitrile butadiene styrene (ABS), or a PC / ABS mixture.

[0046] The plastic material is for example transparent or translucent, in particular for backlighting applications of the decorative layer.

[0047] In this case, the part comprises a light source adapted to inject light into layer 3.

[0048] The first face of this support layer 3 corresponds to the visible side of the part 1. This first face is covered by the decorative layer 5. This decorative layer 5 is typically an ink layer.

[0049] The second face of the support layer 3 is hidden from the passengers of the vehicle.

[0050] The structural part 7 is a part that is typically more massive than the support layer 3. It defines, for example, the attachment points of the part 1 to the structure of the vehicle, or other functional elements of the part.

[0051] The structural part 7 covers all or part of the second face of the support layer 3.

[0052] The decorative layer 5 covers all or part of the first face of the support layer 3.

[0053] The structural part 7 is typically made of a plastic material, for example polycarbonate (PC), polymethyl methacrylate acrylic (PMMA), polypropylene (PP), acrylonitrile butadiene styrene (ABS), or a PC / ABS mixture.

[0054] The method of manufacturing the part will now be described, with reference to Figures 1 to 9.

[0055] This process is of the IMD (In Mold Decoration) type.

[0056] The method comprises a step of introducing a support sheet 11 into a mold 9, the decorative layer 5 being deposited on the support sheet 11. The situation at the end of the introduction step is illustrated in [Fig.l].

[0057] The support sheet 11 has a thickness of between 25 microns and 100 microns, typically being 50 or 75 microns.

[0058] The decorative layer 5 has a thickness of between 5 and 50 microns, typically 15 microns.

[0059] The support layer 3 has a thickness of between 2 and 5 mm, typically 2.5 mm.

[0060] It should be noted that the decorative layer 5, according to an advantageous variant, further comprises:

[0061] - a protective layer of the decorative layer 5 arranged on the decorative layer 5; and / or

[0062] - a layer of glue placed under the decorative layer 5.

[0063] Preferably, a separation layer (not shown) is arranged between the support sheet 11 and the decorative layer 5, the separation layer remaining on the sheet 11 after transfer of the decorative layer onto the part.

[0064] The method then comprises a step of pinching the sheet 11 against a first part 13 of the mold, by a frame 15.

[0065] The first mold part 13 typically comprises a hollow imprint 17. The frame 15 is advantageously arranged over the entire periphery of the hollow imprint 17, and presses a closed-contour area of ​​the sheet 11, in a sealed manner, against the first mold part 13.

[0066] For this purpose, a seal (not shown) is preferably provided between the frame 15 and the first mold part 13. This seal follows the shape of the frame 15, and contributes to obtaining the seal necessary for the step of placing the sheet 11 at the bottom of the hollow surface 17 by suction, described below.

[0067] The method also preferably comprises a step consisting of pressing the sheet 11, bearing the decoration 5, to the bottom of the hollow surface 17. This step is carried out by suction, in other words by drawing a vacuum from the volume delimited between the hollow imprint 17 and the sheet 11. The situation after pressing the sheet is illustrated in [Fig.2].

[0068] The introduction step is performed by moving relative to the first part of mold 13, a continuous film 19 comprising a large number of sheets 11, each sheet 11 carrying a decorative layer 5.

[0069] The film 19 is typically stored in the form of a reel 21, shown schematically in [Fig.l]. During the introduction step, the film 19 is unwound, so as to introduce into the mold 9 a new sheet 11, bearing a decoration 5.

[0070] The sheet 11 used in the previous iteration of the manufacturing process, which no longer includes the decoration 5 because the latter has been transferred to the part 1, is extracted from the mold 9 by the same movement, and is wound onto another reel 23. The movement of the film 19 during the introduction step is shown by an arrow in [Fig.l].

[0071] The frame 15 is typically closed-contour.

[0072] During the introduction step, the frame 15 occupies a position spaced from the first mold part 9 ([Fig.l]), such that the film 19 can be moved relative to the first mold part 13. During the pinching step, the frame 15 is moved relative to the first mold part 13 from the spaced position to a pinching position ([Fig.2]). In the pinching position, the frame 15 bears against the first mold part 13, the sheet 11 being interposed and pinched between the first mold part 13 and the frame 15.

[0073] The method then comprises a step of closing the mold, [Fig.3] illustrating the situation at the end of this closing step.

[0074] This step is carried out by moving the first mold part 13 and a second mold part 25 relative to each other. The first and second mold parts 13, 25 are moved from an opening position of the mold 9 to a closing position of the mold 9. This position is illustrated in [Fig.3].

[0075] In this position, a first surface 27 of the first mold part 13 and a second surface 29 of the second mold part 25 together delimit a cavity 31.

[0076] The first surface 27 here corresponds to the hollow imprint 17.

[0077] The support sheet 11 is engaged in the cavity 31, and extends opposite the first surface 27. The decorative layer 5, carried by the sheet 11, extends opposite the second surface 29.

[0078] After plating, the sheet 11 extends not only opposite but also against the first surface 27.

[0079] The cavity 31 has substantially the shape of the support layer 3.

[0080] The method also comprises a step of injecting the support layer 3 into the cavity 31, between the decorative layer 5 and the second surface 29.

[0081] During this injection step, the decorative layer 5 is transferred onto the support layer 3. The situation at the end of the injection step of the support layer 3 is shown in [Fig.4].

[0082] The method then comprises a step of opening the mold 9. The first mold part 13 and the second mold part 25 are moved relative to each other, from the closed position to the open position. The situation at the end of the mold opening step is illustrated in [Fig.5].

[0083] As visible in this figure, the support layer 3 remains fixed to the first mold part 13 by at least one movable locking member 33 mounted on the frame 15.

[0084] As visible in [Fig.5], the at least one blocking member 33 occupies, relative to the frame 15, a position for blocking the support layer 3.

[0085] In this position, the blocking member 33 delimits a part of the cavity 31, in particular during the injection step.

[0086] The method of the invention then comprises a new step of closing the mold 9, the first surface 27 of the first mold part 13 and another second surface 35 of another second mold part 37 together delimiting another cavity 39.

[0087] The other cavity 39 has substantially the shape of the structural part 7.

[0088] The other second mold part 37 is different from the second mold part 25. It replaces the second part of mold 25.

[0089] The mold is closed by moving the first mold part 13 and the other second mold part 37 relative to each other. In the mold closed position, the support layer 3 is engaged in the other cavity 39 opposite the other second surface 35.

[0090] [Fig.6] illustrates the first mold part carrying the support layer 3, blocked by at least one blocking member 33, as well as the other second mold part 37, before complete closure of the mold 9.

[0091] [Fig.7] illustrates the situation of the mold, at the end of the closing step.

[0092] It should be noted that the other second mold part 37 comes into contact with the layer of support 3 to close cavity 39.

[0093] Alternatively or additionally, the other second mold part 37 comes directly into contact with the first mold part 13 to close the cavity 39.

[0094] Alternatively or additionally, the other second mold part 37 comes into contact with the locking member 33 to close the cavity 39.

[0095] The method then comprises a step of injecting the structural part 7 into the other cavity 39, between the support layer 3 and the other second surface 35.

[0096] [Fig.8] illustrates the situation at the end of the injection step of the structural part.

[0097] The method further comprises a step of moving the at least one locking member 33 relative to the frame 15 to a release position in which the support layer 3 is not fixed to the first mold part 13 by the locking member blockage 33.

[0098] In the example shown, this movement of the at least one locking member 33 relative to the frame 15 from the locking position to the release position is concomitant with the step of closing the mold. It therefore occurs before the step of injecting the structural part 7.

[0099] Alternatively, the step of moving the at least one locking member 33 relative to the frame 15 to the release position is carried out after the injection step. This is possible in particular when the locking member 33 is moved by a hydraulic or pneumatic actuator.

[0100] The method also includes a step of opening the mold 9 and removing the part 1.

[0101] This step is illustrated in [Fig.9].

[0102] The opening and evacuation step is carried out by moving the first mold part 13 and the other second mold part 37, one relative to the other.

[0103] The part 1 comes with the other second mold part 37, because it is no longer blocked by at least one blocking member 33. It is thus removed with the other second mold part 37.

[0104] In the example shown, the other second mold part 37 is moved downwards relative to the first mold part 13 during the mold opening movement.

[0105] Typically, the method further comprises a step of releasing the sheet 11, carried out by moving the frame 15 from the pinching position to the spread position.

[0106] A new iteration of the process is then possible, by introducing into the mold 9 a new support sheet 11, carrying a new decorative layer 5.

[0107] The frame 15 typically comprises several locking members 33, distributed around the periphery of this frame 15, and therefore making it possible to retain the support layer 3 at several points distributed around its periphery.

[0108] Each locking member 33 is advantageously movable in translation relative to the frame 15 between the locking position and the release position.

[0109] Typically, the locking members 33 are movable in translation in a plane perpendicular to the direction D of closing of the mold.

[0110] This direction D corresponds to the direction in which the first mold part 13 and the second mold part 25 move relative to each other during the mold opening and closing operations. The first mold part 13 and the other second mold part 25 move relative to each other in the same direction.

[0111] This direction D is typically rectilinear. It is shown by an arrow in the figures.

[0112] The or each locking member 33 is a finger, or a drawer, or any other member of the same type.

[0113] In the example shown, the or each locking member 33 has a beveled edge 40, of an orientation adapted to retain the support layer 3 against the first mold part 13.

[0114] More precisely, each locking member 33 has a V-shaped end, the beveled edge 40 constituting the wing of the V facing the first surface 27.

[0115] In the locking position, the beveled edge 40 comes to bear against a slice of the support layer 3, urging the latter against the first surface 27 due to its orientation.

[0116] As visible in the figures, the or each locking member 33 is urged towards the locking position by a return member 41 mounted on the frame 15.

[0117] The or each locking member 33 is moved into the release position by a cam member 43 mounted on the other second mold part 37.

[0118] As illustrated in Figures 6 to 9, the cam member 43 is a finger pointing towards the first mold part 13, substantially in the direction of movement D.

[0119] The or each locking member 33 comprises a shape forming a cam follower 45, cooperating with the cam member 43 to move the locking member 33 from its locking position to its release position.

[0120] In the release position, the locking member 33 is offset away from the support layer 3, in a plane perpendicular to the direction of movement D. The beveled edge 40 no longer bears against the peripheral edge of the support layer 3.

[0121] In the example shown, the shape 45 forming a cam follower is an internal surface of an orifice 47 passing through the locking member 33.

[0122] As indicated above, the movement of the first mold part 13 and the other second mold part 37 relative to each other for closing the mold corresponds to a movement of the other second mold part 37 towards the first mold part 13 in the direction D.

[0123] The translational movement of the locking member 33 from its locking position to its release position corresponds to a movement in a direction D', perpendicular to the direction D and shown in [Fig.6].

[0124] The cam surface 43 successively comprises three sections 49, 51, 53. The first section 49 is placed so as to come into contact first with the form 45 forming the cam follower when the mold is closed. The first section 49 is inclined relative to the direction D and relative to the direction D'. It faces towards the first mold part 13 and towards the area of ​​the frame carrying the locking member 33.

[0125] The second section 51 extends the first section 49. It extends in a plane substantially parallel to the direction D.

[0126] The third section 53 extends the second section 51. It has substantially the same orientation as the first section 49.

[0127] The cam follower form 45 comprises a first complementary section 55 and a second complementary section 57. The first complementary section 55 comes into contact with the cam surface 43 when the mold is closed. The second complementary section 57 extends the first.

[0128] The first complementary section 55 is turned both towards the other second mold part 37 and away from the area of ​​the frame 15 carrying the locking member 33.

[0129] The second complementary zone 57 is parallel to the direction D.

[0130] During the closing movement of the mold 9, when the first mold part 13 and the other second mold part 37 move towards each other in the direction D, the first section 49 first comes to bear against the first complementary section 55.

[0131] As the other second mold part 37 approaches the first mold part 13, the first section 49 presses on the first complementary section 55, this press causing a movement of the locking member 33 in the direction D', from the locking position to the release position. This movement is against the return force of the return member 4L

[0132] When the first section 49 reaches the end of the first complementary section 55, the locking member 33 arrives in its release position. The second section 51 then moves against the second complementary section 57, parallel to the direction D.

[0133] As a result, during the end of the movement of the other second mold part 37 along the direction D, the locking member 33 remains stationary in its release position.

[0134] The blocking member 33 remains stationary until the mold is completely closed, and the other cavity 39 is formed.

[0135] During the opening movement of the mold, the other second mold part 37 moves relative to the first mold part 13 in an inverse movement, that is to say in a direction opposite to the direction D shown in the figures.

[0136] In the first part of this movement, the second section 51 slides against the second complementary section 57. The other second mold part 37 therefore moves without causing a shift of the locking member 33 from its release position to its locking position. During this first part of the movement, the part 1 is driven with the other second mold part 37, and passes the nose of the locking member 33.

[0137] The locking member 33 only begins its sliding movement towards its locking position when the support layer 3 has already passed through the locking member. blockage 33.

[0138] A manufacturing assembly of part 1 will now be described.

[0139] This manufacturing assembly is specially designed for the implementation of the manufacturing process above.

[0140] Conversely, the manufacturing method is specially adapted to be implemented by the manufacturing assembly.

[0141] The manufacturing assembly 59 comprises, as illustrated in the figures, a mold 9 comprising a first mold part 13 having a first surface 27 and a second mold part 25 having a second surface 29, the first and second mold parts 13, 25 being movable relative to each other between an open position of the mold 9 and a closed position of the mold 9.

[0142] For this purpose, the manufacturing assembly 59 comprises an actuator 61, shown schematically in the figures, configured to move the first and second mold parts 13, 25 relative to each other between the open position of the mold 9 and the closed position of the mold 9.

[0143] The first and second mold parts 13, 25 are as described above.

[0144] The first surface 27 and the second surface 29 together delimit a cavity 31 in the mold closing position (position of [Fig.3]).

[0145] The cavity 31 has the shape of the support layer 3.

[0146] The first mold part 13 and the second mold part 25 move from the open position to the closed position relative to each other in a translational movement, along the direction D.

[0147] The assembly 59 also comprises a device 62 for introducing a support sheet 11 into the mold 9, the decorative layer 5 being deposited on the support sheet 11.

[0148] As described above, the assembly 59 comprises a continuous film 19 comprising a large number of sheets 11 each carrying a decorative layer 5.

[0149] The film 19 forms a reel 21.

[0150] The introduction device 62 is configured to unwind the reel 21, the sheet 11 used in the previous iteration of the manufacturing method, devoid of decoration 5, being by the same movement extracted from the mold 9 and wound into a reel 23.

[0151] The introduction device 62 comprises means for rotating the reels 21 and 23 and for guiding the film 19. These means are of the conventional type and will not be described here.

[0152] The assembly 59 also comprises a device 63 for pinching the sheet 11 against the first mold part 13 by a frame 15.

[0153] Frame 15 is as described above.

[0154] The pinching device 63 comprises an actuator 64 moving the frame 15 between a pinch position shown in [Fig.2] and a spread position shown in [Fig.l].

[0155] As described above, in the pinching position, the sheet 11 is pinched between the frame 15 and the first surface 27, in a sealed manner.

[0156] It is pinched around its entire periphery.

[0157] In the spaced position of the frame 15, the sheet 11 can be moved relative to the first mold part 13.

[0158] When the first and second mold parts 13, 25 are in the closed position and the sheet 11 is pinched by the frame 15 against the first mold part 13, the support sheet 11 is engaged in the cavity 31 opposite the first surface 27. The decorative layer 5 extends opposite the first surface 27, i.e. opposite the second surface 29.

[0159] The assembly 59 preferably comprises a device 65 for pressing the sheet 11 against the first surface 27, for example by drawing a vacuum from the volume delimited between the sheet 11 and the first surface 27.

[0160] The assembly 59 also comprises a device 67 for injecting the support layer 3 into the cavity 31, between the decorative layer 5 and the second surface 29.

[0161] This injection device 67 is of the conventional type. It is designed to inject the plastic material constituting the support layer 3 into the cavity 31, in the liquid state.

[0162] It should be noted that the decorative layer 5 is transferred onto the support layer 3 during injection. This is obtained due to the nature of the material constituting the decorative layer 5, due to the nature of the material constituting the support sheet 11 and due to the nature of the material constituting the support layer 3. This is well known in the context of an IMD type process.

[0163] The assembly 59 also comprises at least one movable locking member 33 mounted on the frame 15.

[0164] The at least one locking member 33 is movable relative to the frame 15 between a locking position adapted to fix the support layer 3 to the first mold part 13, and a release position adapted so that the support layer 3 is not fixed to the first mold part 13 by the locking member 33.

[0165] The locking member 33 is of the type described above.

[0166] Typically, the assembly 59 comprises a plurality of movable locking members 33, distributed around the periphery of the frame 15, and cooperating with points of the support layer 3 distributed around the periphery of this layer.

[0167] As described above, the or each locking member 33 is movable in translation relative to the frame 15 between the locking position and the release position.

[0168] The frame 15 also comprises a return member 41 urging the or each locking member 33 towards the locking position.

[0169] The return member 41 is preferably mechanically actuated. For example, the return member 41 is an elastic member such as a spring.

[0170] The locking position and the release position are as described above.

[0171] Thus, the at least one movable locking member 33 makes it possible, when the mold 9 is open after injection of the support layer 3, to retain the support layer 3 against the first mold part 13, the latter not being driven by the second mold part 25 when the mold is opened.

[0172] The assembly 59 also comprises another second mold part 37, having another second surface 35, the actuator 61 being configured to move the first mold part 13 and the other second mold part 37 relative to each other between another opening position of the mold 9 and another closing position of the mold 9.

[0173] In the other closed position, the first surface 27 and the other second surface 35 together delimit another cavity 39.

[0174] The support layer 3 fixed to the first mold part 13 by at least one locking member 33 is engaged in the other cavity 39 opposite the other second surface 35.

[0175] The other cavity 39 has the shape of the structural part 7.

[0176] It should be noted that, when the second cavity 39 is formed, the support layer 3 is not necessarily fixed to the first mold part 13 by the locking member 33. Alternatively, it is fixed to the first mold part 13 by the other second mold part 37.

[0177] The assembly 59 also has a device 69 for injecting the structural part 7, shown schematically in Figures 7 and 8.

[0178] The injection device 69 is configured to inject a plastic material into the other cavity 39, in the liquid state, this plastic material constituting the structural part 7. The injection is carried out between the support layer 3 and the other second surface 35.

[0179] This injection device 67 is of the conventional type.

[0180] The assembly 59 also comprises a device 71 for moving the at least one locking member 33 relative to the frame 15 to the release position.

[0181] The displacement device 71 comprises for the or each locking member 33 a cam member 43 mounted on the other second mold part 37.

[0182] This cam member 43 is as described above.

[0183] It is configured to move the locking member 33 from its locking position to its release position when the first mold part 13 and the other second mold part 37 approach each other, during the closing of the mold 9.

[0184] It is also configured to maintain the locking member 33 in its position of release at the start of the opening stroke of the mold 9, i.e. when the other second mold part 37 and the first mold part 13, after injection of the structural part 7, move away from each other.

[0185] The displacement device 71 maintains the locking member 33 in its release position over a sufficient stroke for the part 1 to be evacuated with the other second mold part 37 when the mold is opened, without interference with the or each locking member 33 returning to its locking position.

[0186] The cam member 43 cooperates with a cam follower shape 45, formed on the or each locking member 33.

[0187] The cam member 43 and the cam follower form 45 are as described above.

[0188] The manufacturing process and assembly have multiple advantages.

[0189] Performing the introduction step by moving relative to the first part of mold a continuous film comprising a large number of sheets each carrying a layer of decoration, allows the introduction step to be carried out very efficiently.

[0190] A decorative layer formed from ink is particularly well suited to the process.

[0191] The fact that the or each locking member is movable in translation relative to the frame between the locking position and the release position makes the manufacturing assembly and the corresponding method particularly simple.

[0192] The fact that the or each locking member is urged into its locking position by a return member mounted on the frame also makes it possible to simplify the movement of the or each locking member.

[0193] The fact that the or each locking member is moved into the release position by a cam member mounted on the other second mold part also contributes to simplifying the movement of the or each locking member. The mold therefore does not have to include an actuator dedicated to moving the or each locking member.

[0194] The manufacturing process and assembly may have multiple variants.

[0195] The sheet is not necessarily integrated into a continuous film wound so as to form a reel. The sheets could be introduced one by one, independently of each other.

[0196] The decor layer could be a different layer than an ink layer, provided that it can be transferred to the support layer upon injection, as provided by the IMD process.

[0197] The movement of the first mold part and the second mold part or the other second mold part relative to each other is not necessarily a rectilinear translation, but could be a movement of any other type, for example a rotation.

[0198] The or each locking member could move between its locking position and its release position not in translation but according to another movement, for example comprising a rotation.

[0199] The locking member could be moved between its locking position and its release position by a dedicated actuator.

[0200] Different actuators may be used to move the second mold part and to move the other second mold part.

[0201] The movement of the at least one locking member to its release position may occur not at the time of the second closing of the mold, during the movement of the first mold part and the other second mold part relative to each other, but at another time, for example immediately before the final opening of the mold.

Claims

Claims

1. A method of manufacturing a part (1) comprising a support layer (3), a decorative layer (5) covering a first face of the support layer (3) and a structural part (7) fixed to a second face of the support layer (3) opposite the first face, the method comprising the following steps: - introduction into a mold (9) of a support sheet (11), the decorative layer (5) being deposited on the support sheet (11); - pinching the support sheet (11) against a first part (13) of the mold by a frame (15); - closing the mold (9), a first surface (27) of the first mold part (13) and a second surface (29) of a second mold part (25) together delimiting a cavity (31), the support sheet (11) being engaged in the cavity (31) opposite the first surface (27), the decorative layer (5) extending opposite the second surface (29); - injecting the support layer (3) into the cavity (31) between the decorative layer (5) and the second surface (29), the decorative layer (5) being transferred onto the support layer (3); - opening of the mold (9), the support layer (3) remaining fixed to the first mold part (13) by at least one movable locking member (33) mounted on the frame (15), the at least one locking member (33) occupying, relative to the frame (15), a position for locking the support layer (3); - closing the mold (9), the first surface (27) of the first mold part (13) and another second surface (35) of another second mold part (37) together delimiting another cavity (39), the support layer (3) being engaged in the other cavity (39) opposite the other second surface (35); - moving the at least one locking member (33) relative to the frame (15) to a release position in which the support layer (3) is not fixed to the first mold part (13) by the locking member (33); - injecting the structural part (7) into the other cavity (39) between the support layer (3) and the other second surface (35); - opening of the mold (9) and evacuation of the part (1).

2. A manufacturing method according to claim 1, wherein the step

3.

4.

5.

6.

7. introduction is carried out by moving relative to the first mold part (13) a continuous film (19) comprising a large number of sheets (11) each carrying a decorative layer (5). Manufacturing method according to claim 1 or 2, wherein the decorative layer (5) comprises an ink layer. Manufacturing method according to any one of claims 1 to 3, in which the or each locking member (33) is movable in translation relative to the frame (15) between the locking position and the release position. Manufacturing method according to claim 4, wherein the or each locking member (33) is biased towards the locking position by a return member (41) mounted on the frame. Manufacturing method according to claim 5, wherein the or each locking member (33) is moved into the release position by a cam member (43) mounted on the other second mold part (37). Assembly for manufacturing a part (1) comprising a support layer (3), a decorative layer (5) covering a first face of the support layer (3) and a structural part (7) fixed to a second face of the support layer (3) opposite the first face, the assembly (59) comprising: - a mold (9) comprising a first mold part (13) having a first surface (27) and a second mold part (25) having a second surface (29), the first and second mold parts (13, 25) being movable relative to each other between a mold opening position and a mold closing position, the first surface (27) and the second surface (29) together delimiting a cavity (31) in the mold closing position; - a device (62) for introducing a support sheet (11) into the mold (9), the decorative layer (5) being deposited on the support sheet (11); - a device (63) for pinching the sheet (11) against the first part of the mold (13) by a frame (15), the support sheet (11) being engaged in the cavity (31) opposite the first surface (27), the decorative layer (5) extending opposite the first surface (27); - a device (67) for injecting the support layer (3) into the cavity (31) between the decorative layer (5) and the second surface (27), the decorative layer (5) being adapted to be transferred onto the support layer (3) during injection; - at least one movable locking member (33) mounted on the frame (15), the at least one locking member (33) being movable relative to the frame (15) between a locking position in which the support layer (3) is fixed to the first mold part (13) by the locking member (33) and a release position in which the support layer (3) is not fixed to the first mold part (13) by the locking member (33);- another second mold part (37) having another second surface (35), the first mold part (13) and the other second mold part (37) being movable relative to each other between another mold opening position and another mold closing position, the first surface (27) and the other second surface (35) together delimiting another cavity (39) in the other closing position, the support layer (3) being engaged in the other cavity (39) opposite the other second surface (35) in the other closing position; - a device (69) for injecting the structural part (7) into the other cavity (39) between the support layer (3) and the other second surface (35); - a device (71) for moving the at least one locking member (33) relative to the frame (15) to the release position.;

8. Manufacturing assembly according to claim 7, in which the or each locking member (33) is movable in translation relative to the frame (15) between the locking position and the release position.

9. A manufacturing assembly according to claim 7 or 8, wherein the frame (15) comprises a return member (41) urging the or each locking member (33) towards the locking position.

10. Manufacturing assembly according to any one of claims 7 to 9, in which the displacement device (71) comprises for the or each locking member (33) a cam member (43) mounted on the other second mold part (37).

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