Vehicle interior trim part and its manufacturing process

Abstract

Vehicle interior trim part and manufacturing method thereof The present invention relates to an interior trim part for a vehicle, said trim part having a three-dimensional shape and comprising, on the one hand, a multi-layer structure comprising a support layer (1) and an attached covering layer (2) and, on the other hand, at least one functional element (3) comprising a functional part (3a) of surface extension arranged between the support layer (1) and the covering layer (2). The multi-layer structure further comprises a connecting layer (4) interposed between the support layer (1) and the covering layer (2) so as to assemble / connect them together. At least the functional part (3a) of the functional element (3) is arranged and held locally between the covering layer (2) and the support layer (1) while being located outside the connecting layer (4).It also relates to a method for manufacturing such a part. Figure to be published with the abstract: Fig.1.

Description

Title of the invention: Vehicle interior trim part and method of manufacturing same

[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] The trim (or covering) parts include in particular, 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 very 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 users (drivers and / or passengers) of vehicles and improve their comfort.

[0005] Such a trim piece has an apparent (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 apparent 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 interior of the vehicle and its occupants. Furthermore, the functional element is positioned so that it can be easily connected to a source power supply or 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 particularly toward a user of the vehicle) 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 DE 102015220253, use at least two specific and separate connecting 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.

[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 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 element functional, preferably of thin thickness, comprising a functional part of surface extension 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, characterized in that the multilayer structure further comprises 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 / link them together and in that at least the functional part of the or at least one of the functional element(s) is arranged and maintained locally between the covering layer and the support layer while being located outside the connecting 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 covering layer covering,completely or partially, the support layer, the multilayer 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 / link 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.

[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 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:

[0013] - provide at least one functional element,

[0014] - place the or each functional element in the mold while holding it in a predetermined position in the first part of the mold,

[0015] - close the mold so as to form an injection chamber and inject 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,

[0016] - to open the mold to unmold 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,

[0017] - providing a covering layer and fixing it to the support layer by means of 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.

[0018] 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:

[0019] [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,

[0020] [Fig.2] is a sectional view of a trim piece according to the present invention, in one embodiment of the covering layer comprising a comfort layer and completely covering the support layer,

[0021] [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,

[0022] [Fig.4] is a sectional view of a trim piece according to the present invention, according to a particular embodiment of the part shown in [Fig.3],

[0023] [Fig.5] is a sectional view of a trim piece according to the present invention, in a particular embodiment of the support layer,

[0024] [Fig.6] is a top view of a functional element,

[0025] [Fig.7] is a sectional view of the functional element shown in [Fig.6],

[0026] [Fig.8] is a sectional view of an injection mold that can be used to place implement the method according to the present invention,

[0027] [Fig.9],

[0028] [Fig. 10],

[0029] [Fig. 11],

[0030] [Fig. 12],

[0031] [Fig. 13] show the mold shown in [Fig.8] in use in the different steps of the process preceding the step of fixing the covering layer to the support layer by the bonding layer, called the last step,

[0032] [Fig. 14] illustrates the last step of the process.

[0033] Figures 1 to 7 show an interior trim piece, according to the present invention, for a vehicle, said trim piece having a three-dimensional shape and comprising:

[0034] - a multilayer structure comprising a support layer 1 having two faces opposite, 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 an apparent face of the trim piece and an internal face 2b facing the internal face 1b of the support layer 1, and

[0035] - 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. The functional part 3 extending continuously (i.e. without electrical discontinuity due for example to an electrical connection or connection) by an elongated connection or joining part 3b allowing its electrical supply and / or the transmission of electrical signals.

[0036] Such a piece of trim (or covering) may include, in particular, but not limited to, dashboards, door panels, central console panels, window pillars, and similar cabinetwork pieces.

[0037] 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.

[0038] According to the present invention, in such a trim piece, the multilayer structure further comprises (or includes) a bonding layer 4 interposed between the support layer 1 and the covering layer 2 while being fixed on the internal faces 1b, 2b of the latter so as to assemble (or bond) them together.

[0039] 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.

[0040] An added layer is understood to mean a layer which does not originate from the manufacture with the support layer 1, for example in a mold by injection of plastic material and overmolding.

[0041] 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 attachment of the support layer 1 with the covering layer 2 while limiting the surface and the amount of bonding layer 4 used. This embodiment is not illustrated by the accompanying drawings.

[0042] 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.

[0043] Still in accordance with the present invention, 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 precise points on the surface or volume of the trim piece, 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, i.e. 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.

[0044] The covering layer 2 can completely ([Fig. 1 ]) or partially (figures 3 and 4) cover 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 apparent 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 apparent (or visible) face of the trim piece. In this case there may be an offset between these surfaces at the level of the apparent 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 slope (figures 3 and 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 slope (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 slope, in this case only part of the thickness of the covering layer 2 extends into the housing and the other part to the outside.

[0045] In a variant of the case where the covering layer 2 partially covers the support layer 1, as can be seen in [Fig. 4], the periphery of the covering layer 2 can be materialized in the support layer 1 by an arrangement, or a geometric characteristic, the 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.

[0046] If we now refer, in particular, to Figures 6 and 7, we can see 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.

[0047] Preferably, it can be seen in [Fig. 5] that the present invention can provide that the support layer 1 has a honeycomb structure integrating, for example, encapsulated air bubbles Id 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.

[0048] Preferably, the bonding layer 4 is made from an adhesive or glue, for example of the polyurethane, acrylic or polypropylene type.

[0049] Preferably, the support layer 1 is a layer of injected material, preferably of injected plastic material, for example of the polypropylene type.

[0050] 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:

[0051] - either with the internal faces 1b, 2b of the support layers 1 and covering 2 (shape not illustrated by the attached figures),

[0052] - either, such as the shape illustrated in Figures 1 to 5, with the internal face 1b of the support layer 1 and bonding layer 4,

[0053] - either with the internal face 2b of the covering layer 2 and the bonding layer 4 (form not illustrated by the attached figures).

[0054] In a preferred embodiment illustrated in [Fig.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(s) 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 thereto 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.

[0055] The connection or joining part 3b of the or at least one of the functional element(s) 3 can pass 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.

[0056] 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.

[0057] The present invention also relates to a method for producing an interior trim piece for a vehicle, said trim piece possibly being a trim piece as described previously. More particularly, in such a trim piece 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 bonding layer 4 or with the covering layer 2.

[0058] 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:

[0059] i) providing at least one functional element 3 ([Fig.9]),

[0060] ii) placing the or each functional element 3 in the mold M while maintaining it in a predetermined position in the first part Ml of the mold M ([Fig. 10]),

[0061] iii) closing the mold M, that is to say by bringing together and mutually contacting the two moving parts M1, M2, so as to form an injection chamber M3 ([Fig.11]) and to inject 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),

[0062] iv) opening the mold to demold and extract the support layer 1 provided with the functional element(s) 3, possibly with the elongated connecting or joining part 3b thereof passing through the material of the support layer 1 ([Fig. 13]),

[0063] v) providing a covering layer 2 and fixing it to 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 ([Fig. 14]).

[0064] 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:

[0065] - by spreading, for example by means of a brush, a roller, or

[0066] - by spraying, for example using a gun.

[0067] The spreading of the glue or adhesive can be carried out manually or (automatically) using a robot.

[0068] The first part Ml of the mold M may comprise a punch Mil in which the sealed cavity Ml 10 may be made. Such a mold is described for example in the document FR2200727.

[0069] 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 part 33b of the elongated connection or joining part 3b is housed in a sealed cavity M1 10 of the first part M1 of the mold, more particularly of the punch MIL. 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 part 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.

[0070] 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.

Claims

Claims

1. 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 (1) having two opposite faces, namely an external face (1a) and an internal face (1b) and a covering layer (2) attached 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, on the other hand, 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), the multi-layer structure further comprising a connecting layer (4) interposed between the support layer (1) and the covering layer (2) while being fixed on the internal faces (1b,2b) of the latter so as to assemble / link them together, at least the functional part (3a) of the or at least one of the functional element(s) (3) being arranged and held locally between the covering layer (2) and the support layer (1) while being located outside the connecting layer (4), characterized in that the functional part (3a) is continuously extended by an elongated connection or joining part (3b) allowing its electrical supply and / or the transmission of electrical signals and in that the elongated 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 (la) while being embedded in or coated by the support layer (1).,

2. A trim piece according to claim 1, characterized in that the bonding layer (4) is made from an adhesive or glue.

3. Trim piece 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 piece according to any one of claims 1 to 3, characterized in that at least the functional part (3a) of the or 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 covering (2) layers, or with the internal face (1b) of the support layer (1). and the bonding layer (4), either with the internal face (2b) of the covering layer (2) and the bonding layer (4).

5. Trim piece, according to any one of claims 1 to 4, characterized in that the covering layer (2) comprises 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).

6. A piece of trim according to claim 5, characterized in that the comfort layer (2d) is made from a foam, preferably a synthetic foam, preferably of the polyurethane, polyethylene or polypropylene type.

7. Trim piece according to any one of claims 1 to 6, characterized in that the covering layer (2) partially covers the support layer (1).

8. Trim piece, according to claim 7, characterized in that the periphery of the covering layer (2) is materialized in the support layer (1) by an arrangement, or a linear geometric characteristic, (le) in the form of a hollow, for example of the groove type, made in the internal face (la) of the support layer (1) and receiving at least the peripheral edge (2e) of the covering layer (2).

9. Trim piece according to any one of claims 1 to 8, characterized in that the covering 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 piece according to any one of claims 1 to 9, characterized in that the support layer (1) has a honeycomb structure integrating, for example, encapsulated air bubbles (Id) making it possible to obtain a thermal conductivity of the support layer (1) lower than that of the covering layer (2).

11. 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 (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 face visible surface of the trim piece and an internal face (2b) facing the internal face (1b) of the support layer (1) and, on the other hand, 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) and extending continuously by an elongated connection or joining part (3b) allowing its electrical supply and / or the transmission of electrical signals, the multilayer structure further comprising a connecting layer (4) interposed between the support layer (1) and the covering layer (2) while being fixed on the internal faces (1b, 2b) of the latter so as to assemble / connect them together,at least the functional part (3a) of the or at least one of the functional element(s) (3) being arranged and held locally between the covering layer (2) and the support layer (1) while being located outside the connecting layer (4), method 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):, - provide at least one functional element (3), - placing the or each functional element (3) in the mold (M) while maintaining it in a predetermined position in the first part (Ml) of the mold (M), - closing the mold (M) so as to form an injection chamber (M3) 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, - opening the mold (M) 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),

12. - providing a covering layer (2) and fixing it to 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 at least the functional part (3a) of the or at least one of the functional element(s) (3) is located outside the area occupied by the bonding layer (4). Method according to claim 11, characterized in that the bonding layer (4) is a glue or adhesive applied to the support layer (1) and / or to the covering layer (2), and optionally to the functional part (3a) of the or 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.

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