Interior trim panel component for vehicle

Abstract

Vehicle Interior Trim Panel Component The present invention relates to a component (1) of a vehicle interior trim panel comprising: a rigid backing layer (2), this backing layer (2) predominantly comprising at least one thermoplastic, in particular of the polypropylene type; a covering layer (3), of the non-woven textile type, superimposed, directly or indirectly, on the backing layer (2), this covering layer (3) comprising at least one blend of thermoplastic fibers, of the polypropylene or polyester type, with a physicochemical composition different from that of the backing layer (2), characterized in that the blend of the covering layer (3) also comprises pieces of textile (30) substantially arranged in the plane of the covering layer (3). Figure to be published with the abstract: Fig. 5

Description

Title of the invention: Interior trim panel component for vehicle

[0001] The present invention relates to the field of trim panels for vehicle interiors and more particularly to the field of trim panels with reduced carbon impact.

[0002] In the context of current environmental issues, the importance of environmental challenges is forcing manufacturers to reduce the carbon footprint of their products. The automotive industry, which until now has been closely linked to fossil fuels and the petrochemical industry, is now compelled to consider its environmental impact. This consideration of environmental factors in the design of automotive products aims to reduce CO2 emissions in the production of vehicle parts.

[0003] Interior trim panels, which are also products of the automotive industry, are no exception to this concern for optimizing the reduction of carbon footprint. Thus, solutions have been developed based on the substitution of materials with recycled materials in order to reduce the carbon footprint of the vehicle parts produced. However, the integration of recycled materials into vehicle parts is confronted, firstly, with the safety requirements defined by the standards in force in the field, but also, particularly for parts such as those used in vehicle interior trim, with aesthetic constraints that meet, on the one hand, the requirements of manufacturers' specifications and, on the other hand, commercial imperatives.Thus, not all vehicle parts allow, or only marginally permit, this incorporation of recycled materials, particularly in the context of direct visual incorporation.

[0004] Solutions for incorporating recycled materials into vehicle parts have already been developed. Publication FR3139521 proposes a solution for recycling textiles by incorporating them into vehicle interior trim. This technology essentially consists of reducing textiles into fibers, for example by grinding or shredding, so that they can be easily mixed with various plastic components of interior parts. While this solution is effective, it remains restrictive because it requires that the various textiles to be recycled be reduced beforehand into a specific form. This tedious preliminary step of reducing the textiles is therefore essential for the operation of recycling itself is not efficient. Besides requiring energy, the duration of the recycling process is also lengthened.

[0005] The present invention aims to overcome these drawbacks by proposing a trim panel element for vehicle interiors which facilitates the integration of at least one recycled material into a vehicle part so that this integration retains, on the one hand, qualities of mechanical performance in use and safety while allowing, on the other hand, a diversity of variations in appearance in response to possible aesthetic requirements.

[0006] The invention relates to a trim panel component for a vehicle interior comprising: - a rigid support layer, this support layer comprising mainly at least one thermoplastic, in particular of the polypropylene type, - a coating layer, of the non-woven textile type, superimposed, directly or indirectly, on the support layer, this coating layer comprising at least one mixture of thermoplastic fibers, of the polypropylene or polyester type, according to a physicochemical composition different from that of the support layer, characterized in that the coating layer mixture also includes pieces of textiles substantially arranged in the plane of the coating layer.

[0007] The invention also relates to a method for manufacturing a trim panel component for a vehicle interior according to the invention, characterized in that the method comprises at least: - a preparation phase for the coating layer, this preparation including at least one step of collecting and selecting textile pieces intended for recycling, - a phase of assembly and fixing, direct or indirect, of the coating layer to the support layer, characterized in that the coating layer preparation phase also includes: - a step of mixing textile pieces with thermoplastic fibers, such as polypropylene and / or polyester, - a step of binding the mixture to obtain a non-woven textile-type material, - a step of cutting the material to the desired dimensions in order to produce at least part of the coating layer of the part.

[0008] The invention will be better understood from the following description, which relates to preferred embodiments, given by way of non-limiting examples, and explained with reference to the accompanying schematic drawings, in which:

[0009] [Fig-1] represents a top and cross-sectional view of an example of a trim panel component of the invention,

[0010] [Fig.2] represents a front cross-sectional view of a trim panel piece from [Fig.1],

[0011] [Fig.3] represents a front sectional view of an example of a trim panel component incorporating additional elements,

[0012] [Fig.4] shows a front cross-sectional view of an example of a trim panel component incorporating a protective layer,

[0013] [Fig.5] represents a front cross-sectional view of an example of a trim panel piece in which pieces of textiles are integrated into the coating layer.

[0014] In this document, the term "thermoplastic" refers to a compound, the material of which is of synthetic origin, in particular plastic, which preferably has a structural form of fiber, and has the property, on the one hand, of a loss of rigidity under the effect of heat and, on the other hand, of hardening upon cooling.

[0015] In this document, the term “textile” refers to all textiles, regardless of their nature and / or origin.

[0016] The present invention relates to a trim panel 1 for a vehicle interior comprising: - a rigid support layer 2, this support layer 2 comprising mainly at least one thermoplastic, in particular of the polypropylene type, - a non-woven textile coating layer 3, superimposed, directly or indirectly, on the support layer 2, this coating layer 3 comprising at least one mixture of thermoplastic fibers, of the polypropylene or polyester type, according to a physicochemical composition different from that of the support layer 2, characterized in that the mixture of the coating layer 3 also comprises pieces of textiles 30 substantially arranged in the plane of the coating layer 3.

[0017] It should be noted that the vehicle interior trim panel 1 according to the invention is suitable for integration into any type of vehicle, including land vehicles such as automobiles, trucks, utility vehicles, or construction vehicles, but also inside aircraft or marine vehicles, particularly if they are capable of carrying one or more passengers. By way of example, the vehicle interior trim panel 1 relates to a dashboard, door panel or console, or even a headliner trim, shelf or windshield or window frame of the vehicle.

[0018] The trim panel component 1 according to the invention thus incorporates a superposition of layers 2 and 3 in which the respective support and coating functions are ensured. Therefore, the trim panel component 1 is suitable for use in a vehicle interior, while also allowing for a layer design using recycled materials, thereby reducing the carbon footprint of manufacturing the component 1. Furthermore, given their respective compositions, the support layer 2 and coating layer 3 of the trim panel component 1, in combination, are able to meet safety requirements and aesthetic constraints.

[0019] In the present invention, the thermoplastic fibers are preferably made of synthetic resins, in particular compounds used in the manufacture of plastics. Preferably, in order to optimize the reduction of the carbon footprint in vehicle production, the thermoplastic fibers used come from a plastics recycling stream. This optimization is further achieved because, given their heat-dependent "reversible thermoplasticity" properties, these thermoplastic fibers are infinitely recyclable.

[0020] Thanks to the aforementioned properties of thermoplastic fibers, they offer the advantage of being easily used as a matrix or binder in a process involving heating operations with temperature variation or compression operations. These heating operations, in particular, make the thermoplastic material malleable in the production of the trim panel part 1 by heating it to a temperature above the softening temperature of the thermoplastic fibers.

[0021] In the context of trim panel part 1 of the invention, the thermoplastic fibers of the support layer 2 are polypropylene compounds. These compounds optimally meet a compromise between mechanical performance, ease of production, and cost, while also complying with the specifications imposed on vehicles. In contrast, the thermoplastic fibers for the coating layer 3 have a different physicochemical composition than the support layer 2 and are a combination of polypropylene and polyester. This difference in composition allows them to fulfill the structural and functional roles that each of these two layers 2 and 3 plays in the trim panel part 1. Indeed, the support layer 2 supports the coating layer 3, while the coating layer 3 provides a unique and original decorative surface that is capable of characterizing The appearance of part 1 is designed to meet users' aesthetic expectations while maintaining its stability over time. A different physicochemical composition allows each layer to fulfill its role without compromising the structural requirements and physicochemical properties that the trim panel part 1 must meet.

[0022] According to an embodiment relating to a variant of the construction of the trim panel part 1 of the invention, the material mixture of the coating layer 3 is made by combining, on the one hand, 5% to 15%, preferably in the order of 6% to 10%, ideally in the order of 8% of a mixture in identical or even similar proportions of co-extruded bi-component fibers of polypropylene and polyester and, on the other hand, 20% to 40%, preferably in the order of 25% to 35%, ideally in the order of 30% of polypropylene fibers, the rest of the material of the mixture being supplied by the textile parts 30 integrated into the coating layer 3.

[0023] Preferably, the thermoplastic material of the coating layer 3 is made from co-extruded, two-component polypropylene and polyester fibers, in which each fiber comprises a polypropylene core surrounded by a polyester sheath. Since the melting point of the polyester sheath is lower than that of the polypropylene core, the polyester can be melted, and thus the thermoplastic fibers can be bonded to each other and to the textile pieces 30 in the coating layer 3 without the polypropylene core melting. The polyester alone is sufficient to create cohesion between the fibers and to the textile pieces 30. Under these conditions, the polyester acts as a binder for bonding the polypropylene fibers to the textile pieces 30. The melting temperature used can then be between 160° Celsius and 170° Celsius.

[0024] Within the framework of the invention, the support layer 2 thus exhibits mechanical rigidity properties superior to those of the coating layer 3. Under these conditions, the support layer 2 fulfills its role of support by providing structural rigidity to the trim panel part 1 of the invention without altering or impacting the specific technical properties of the coating layer 3.

[0025] The integration of textile pieces 30 in a simply cut or torn form, without requiring a state corresponding to a totally degraded textile in a frayed form, allows the textile pieces 30 to be used in a format approaching their native state and thus eliminates the need for a grinding or fraying operation to prepare the textile pieces 30, thereby meeting industrial requirements for the production of trim panel pieces 1 which impose a reduced carbon impact. Indeed, in the context of the production of a piece 1 of trim panel and more particularly of its coating layer 3, the elimination of the grinding or shredding of the textile pieces 30 makes it possible to reduce the duration of the manufacturing process and to operate a consequent limitation of the amount of energy required to prepare these textile pieces 30.

[0026] The textile pieces 30 generally have flexible and substantially flat structures. Therefore, in the context of a trim panel piece 1 of the invention, these textile pieces 30 can be easily arranged in the plane of the coating layer 3 of the trim panel piece 1. Furthermore, given the flexibility of the textile pieces 30, they can readily adapt to and conform to any curvatures and surface variations of the coating layer 3. The textile pieces 30 are arranged to be distributed within the coating layer 3 so as to be positioned at the surface level of the coating layer 3 and / or within the depth or thickness of the coating layer 3.Furthermore, given their flexibility, the textile pieces 30 are also likely to have, on the one hand, a first part positioned at the level of the surface of the coating layer 3 and, on the other hand, a second part disposed deeper in the thickness of the coating layer 3.

[0027] Integrating the textile pieces 30 within the coating layer 3, in combination with the polypropylene and polyester blend, allows for positioning and maintaining this positioning within the thickness of the coating layer 3, particularly at a defined depth. The textile pieces 30 are thus embedded in the polypropylene and polyester blend. Preferably, the thermoplastic blend of the coating layer 3, combining polypropylene and polyester, provides a structural binder that is at least substantially transparent, or even translucent, i.e., allowing at least the visible spectrum of light to pass through this thermoplastic blend.Under these conditions, the textile pieces 30 embedded in the thermoplastic material of the coating layer 3 remain visible from the outer surface of the trim panel piece 1 through the transparent or translucent thermoplastic material. The textile pieces 30 thus contribute to the visual, even aesthetic, appearance of the outer surface of the coating layer 3. The thermoplastic compound of the coating layer 3, which forms the material in which the textile pieces 30 are embedded, allows for the creation of an outer surface of the coating layer 3 that is rigid and resistant despite the visual appearance provided by the textile pieces 30.

[0028] According to an embodiment relating to a variant of the construction of the trim panel component 1 of the invention, the textile pieces 30 of the coating layer 3 are arranged so as to be at least partially overlapping. Therefore, when these textile pieces 30 are distributed within the coating layer 3, they can be positioned at respective depths different from the thickness of the coating layer 3.Under these conditions, when the distribution of the different textile pieces 30 in the coating layer 3 is carried out in a random manner, they are then led to overlap each other so that, for example, a first part of a textile piece 30 is superimposed on a second textile piece and a second part of this same textile piece 30 is positioned under a third textile piece, the first and second parts of the textile piece 30 being likely to be arranged at the same or different levels of the thickness of the coating layer 3. It should also be noted that the random aspect of the distribution of the textile pieces 30 is likely to be compounded by the variations in shape and size adopted by each of the different textile pieces 30.The appearance thus given by the different pieces of textiles 30 arranged in the coating layer 3 is then that of a patchwork of textiles embedded in the thermoplastic mixture of the coating layer 3.

[0029] According to an embodiment relating to another construction variant of the trim panel part 1 of the invention and capable of being combined with one or the other of the previously detailed construction variants, the textile pieces 30 of the coating layer 3 are arranged to be distributed over the entire coverage surface of the coating layer 3. According to this construction variant, the translucent and / or transparent nature of the thermoplastic mixture of the coating layer 3 then allows the creation of a coating layer 3 of the trim panel part 1 whose visual appearance is entirely rendered by the different textile pieces 30.Furthermore, the distribution of the textile pieces 30 occurring at different levels of the coating layer 3, the translucent and / or transparent nature of the thermoplastic mixture which embeds these textile pieces 30 allows a visual aspect of depth to appear in the coating layer 3, in particular when the difference in positioning level between two portions of textile pieces 30 juxtaposed in the thickness of the coating layer 3 is significant.

[0030] According to an embodiment relating to another construction variant of the trim panel part 1 of the invention and forming an alternative to the construction variant detailed above, the textile pieces 30 of the coating layer 3 are arranged to leave areas free of pieces of textiles 30 at certain points on the surface covering the coating layer 3. According to this construction variant, the translucent and / or transparent nature of the thermoplastic mixture of the coating layer 3 makes it possible to make visually accessible the surface of the material layer on which the coating layer 3 is positioned at the level of the areas of the coating layer 3 devoid of pieces of textiles 30. The surface of the material layer on which the coating layer 3 is positioned is thus able to participate indirectly, through the thermoplastic material, in the visual appearance of the trim panel piece 1 of the invention.Furthermore, depending on the thickness of the coating layer 3, the visual appearance of this coating layer 3 is also likely to reveal depth thanks to the translucent and / or transparent nature of the thermoplastic mixture that embeds the textile pieces 30, particularly when the difference in positioning level of the textile pieces 30 positioned on the surface and the surface of the material layer on which the coating layer 3 is positioned is significant.

[0031] According to an embodiment relating to another construction variant of the trim panel part 1 of the invention and capable of being combined with either of the previously detailed construction variants, the coating layer 3 has an average thickness of less than 10 millimeters, preferably between 2 and 8 millimeters, prior to its possible compression or thermocompression. The thickness of this coating layer 3 is at least greater than the thickness of a piece of textile 30 to be integrated into the coating layer 3. Preferably, this thickness is at least twice the thickness so as to allow for at least partial overlap between two juxtaposed pieces of textile 30.Depending on the thickness of this coating layer 3, the translucent and / or transparent thermoplastic mixture that embeds the textile pieces 30 will be able to create a visual appearance of depth on the surface of the trim panel piece 1.

[0032] According to an embodiment relating to another construction variant of the trim panel part 1 of the invention and capable of being combined with either of the previously detailed construction variants, the panel part 1 comprises an intermediate layer 6 positioned between the coating layer 3 and the support layer 2, this intermediate layer 6 being arranged to cover the entire surface of the support layer 2. This intermediate layer 6 thus provides coverage of the support layer 2 such that, when the thermoplastic material of the coating layer 3 is translucent and / or transparent, the surface of the intermediate layer 6 is likely to be visible between different pieces of textiles 30 through the coating layer 3, so that the intermediate layer 6 is capable of contributing to the visual appearance of the trim panel part 1 of the invention. This intermediate layer 6 is capable of taking the form of a film or a textile, for example a printed and / or colored textile, so as to allow a visual effect by transparency through a part of the coating layer 3.

[0033] According to an embodiment relating to another construction variant of the trim panel part 1 of the invention and capable of being combined with the construction variant detailed above, the intermediate layer 6 comprises at least one mixture of thermoplastic fibers, such as polypropylene or polyester, and shredded textile fibers. By way of example, these shredded textile fibers may correspond to fibers, of natural or synthetic origin, such as polyethylene, polyester, flax, hemp, kenaf, miscanthus, wool, elastane, cotton, or polyamide fibers.

[0034] According to an embodiment relating to another construction variant of the trim panel part 1 of the invention and capable of being combined with either of the previously detailed construction variants, the coating layer 3 comprises an outer surface 31, opposite the facing surface of the support layer 2, which has at least one relief and / or a non-smooth arrangement. A non-smooth arrangement corresponds in particular to a surface relief that would not be visually observable but would be identifiable by contact with the outer surface 31, so as to allow tactile perception, for example, of a graininess or roughness of that surface 31.According to one embodiment, the coating layer 3 may have a raised surface 31 visible to users of the trim panel component 1, obtained, for example, by embossing or graining, and contributing to the aesthetic appearance of the trim panel component 1. According to another embodiment, the coating layer 3 may have a non-smooth arrangement on its outer surface 31, visible to users of the trim panel component 1, for example, in the form of a surface grain. Thus, the trim panel component 1 according to the invention may have a coating layer 3 that combines an aesthetic appearance, with raised surfaces and / or a non-smooth arrangement, thanks to an eco-responsible, low-carbon design involving partial or complete manufacturing using textile components 30 from a recycling stream.

[0035] According to an embodiment relating to another construction variant of the trim panel part 1 of the invention and capable of being combined with either of the previously detailed construction variants, the part 1 also includes a protective layer 4 positioned on at least a part of the outer surface 31 of the coating layer 3, i.e. opposite the surface of the coating layer arranged opposite the support layer 2, This protective layer 4 may be at least partially transparent or translucent. This protective layer may, for example, be a varnish, lacquer, or film. Such a protective layer 4 optimizes the long-term maintenance of the appearance of the outer surface 31 of the coating layer 3, notably by protecting it against damage related to its use. This protective layer 4 may also enhance the visual appearance of the outer surface 31 according to its inherent characteristics, so that the specific appearance or color properties of this protective layer 4 can be combined with the intrinsic properties of the outer surface 31 to visually modify the appearance of the coating layer 3.For example, this protective layer 4 is likely to impart a particular tint or a glossy appearance to at least part of this outer surface 31 of the coating layer 3, thus providing an additional decorative or textured pattern.

[0036] The invention also relates to a method for manufacturing a part 1 of a trim panel for a vehicle interior according to the invention, the method comprising at least: - a preparation phase for the coating layer 3, this preparation including at least one step of collecting and selecting textile pieces 30 intended for recycling, - a phase of assembly and fixing, direct or indirect, of the coating layer 3 to the support layer 2, characterized in that the preparation phase of coating layer 3 also includes: - a step of mixing 30 pieces of textiles with thermoplastic fibers, such as polypropylene and / or polyester, - a step of binding the mixture to obtain a non-woven textile-type material, - a step of cutting the material to the desired dimensions in order to produce at least part of the coating layer 3 of part 1.

[0037] According to an embodiment relating to a particular variant of the preparation phase of the coating layer 3, the step of mixing textile pieces 30 with thermoplastic fibers is carried out by air mixing. This step of mixing the textile pieces 30 involves AIRLAID technology, also known as "airflow" technology, which consists of an aerodynamic process that carries and disperses the textile pieces 30 with the thermoplastic fibers of the mixture in an airflow so as to subsequently bind them together.

[0038] According to an embodiment relating to another variant of the process of the invention and capable of being combined with either of the variants detailed above, the bonding step of the mixture is carried out by heating and rolling and / or calendering the mixture. Heating the mixture formed by the textile pieces 30 and the thermoplastic fibers provides thermal energy to melt, in particular, the thermoplastic fibers to embed the various textile pieces 30, so that the entire mixture, once heated, results in the formation of a non-woven textile-type material. By way of example, the heating operation is carried out at a temperature of approximately 160° Celsius to 170° Celsius in order to melt at least a portion of the thermoplastic material intended to form the coating layer 3.Preferably, this heating operation of the mixture is complemented by laminating and / or calendering the mixture so that the various components of the coating layer 3, which combine the textile pieces 30 and the thermoplastic fibers, are compressed into a densified whole. This laminating and / or calendering of the coating layer 3 can be carried out by moving a roller against a surface of the mixture intended to form the coating layer 3, or by moving the mixture between two closely spaced, counter-rotating rollers. This at least one moving roller can also be a heated roller, enabling the mixture to be heated as well, or potentially optimizing the laminating operation, or even complementing the heating operation during the laminating or calendering of the mixture.

[0039] According to an embodiment relating to another variant of the process of the invention and capable of being combined with either of the variants detailed above, on the one hand, the recycled textile pieces 30 have dimensions ranging from 3 mm to 120 mm and, on the other hand, the thermoplastic fibers have dimensions ranging from 2 mm to 20 mm. It should be noted that the dimensions of the textile pieces 30 are essentially determined by the prior cutting of the textiles carried out before mixing the textile pieces 30 with the thermoplastic material. Preferably, the recycled textile pieces 30 have dimensions ranging from 20 mm to 60 mm. The choice of dimensions for the textile pieces 30 is also determined according to the desired visual appearance of the surface of the coating layer 3.

[0040] According to an exemplary embodiment relating to another variant of the method of the invention and capable of being combined with one or the other of the variants detailed above, the assembly phase of the coating layer 3 onto the support layer 2 involves: - a positioning step of the coating layer 3 in a mold, - a thermocompression operation. During the positioning step, the coating layer 3 is positioned against the support layer 2. During the thermocompression operation, the thermoplastic material is melted, notably by heating to approximately 200°C, and then the malleable assembly of the two superimposed layers 2 and 3 is formed by compression before being cooled to ambient temperature. Alternatively, the support layer 2 is heated prior to the positioning of the coating layer 3 and the forming step as part of the thermocompression operation.

[0041] According to a specific embodiment of this first variant, the mold surface in contact with the coating layer 3 has a relief with a pattern or surface grain. This pattern then makes it possible, during the thermocompression operation, to create at least one visible relief and / or non-smooth arrangement on the outer surface 31 of the coating layer 3. Additionally, for the purpose of carrying out a thermocompression operation, the preliminary mixing step can be applied to textile fibers, thermoplastic fibers, and reinforcing fibers so that these reinforcing fibers increase the mechanical strength properties of the trim panel part 1.

[0042] According to another complementary example of a specific implementation of this first variant, the thermocompression operation in the mold involves a compression of approximately 10 bar at a temperature of approximately 200°C. Such a non-limiting example of implementation allows for the subsequent demolding of the trim panel part 1 without difficulty.

[0043] According to an embodiment of the method of the invention relating to a specific variant of the first embodiment of the assembly phase of the coating layer 3 onto the support layer 2, the method of the invention further comprises an overmolding operation of at least one additional element 5 by injection, this additional element 5 being able to be an index, a fastening means, a clip, or even a rib. Preferably, the additional elements 5 are positioned on the face opposite the support layer 2. Moreover, these additional elements 5 are made of injected thermoplastic resin, such as polypropylene.

[0044] According to an example of an embodiment relating to a second variant of the assembly phase of the coating layer 3 onto the support layer 2, this involves at least one material injection operation. This injection is preferably carried out on the surface of the coating layer 3 that faces the support layer 2.

[0045] According to a particular embodiment of this second variant of the assembly phase of the coating layer 3 onto the support layer 2, this involves at least: - a step of positioning the coating layer 3 in a mold, - an injection step into the mold of the material intended to form the layer support 2 so as to perform an overmolding of the coating layer 3 by the support layer 2.

[0046] According to a preferred example of this second variant of the assembly phase, the material injection operation is carried out in a mold capable of having a relief and / or a non-smooth arrangement, to interact with an injected material based on thermoplastic resin, in particular of the polypropylene type, intended to form the support layer 2.

[0047] According to an example relating to another variant of the manufacturing process of the invention, which can be combined with the other variants detailed above, the assembly phase of the coating layer 3 onto the support layer 2 involves at least one bonding and / or sheathing operation using at least one adhesive material and / or glue. Following the implementation of this variant, after assembly, the trim panel part 1 comprises at least one intermediate layer of adhesive or glue disposed between the support layer 2 and the coating layer 3. Preferably, the adhesive material or glue selected for this operation is of the polyurethane, polyamide, or polyester type.

[0048] According to an example of an embodiment relating to another variant of the manufacturing process of the invention, which can be combined with the various variants detailed above, the process further includes a step of positioning and fixing a protective layer 4 on at least a part of the outer surface 31 of the coating layer 3, i.e. opposite the surface of the coating layer 3 arranged opposite the support layer 2. According to a preferred embodiment of this positioning and fixing step, the protective layer 4 is arranged so as to cover the entire outer surface 31 so that the entire part of the coating layer 3 which is visible to users is protected.According to a specific example of this embodiment, the protective layer 4 is applied to the outer surface 31 by spraying with a spray gun, or by using a brush or roller. Preferably, but not limited to, the protective layer 4 consists of a varnish, lacquer, or transparent protective film, protecting the visual and structural appearance of the outer surface 31 from the coating layer 3 of the trim panel part 1. According to a particular example, the transparent film may incorporate various decorations produced by printing such as inkjet or [other methods]. pad printing to complement the effect provided by the coating layer 3 of the trim panel part 1.

[0049] In an implementation of the process of the invention comprising an assembly phase of the coating layer 3 onto the support layer 2 involving a thermocompression operation according to the first embodiment detailed above, when the protective layer 4 is made of a transparent protective film, the positioning and fixing of this transparent film onto the coating layer 3 can be carried out after the thermocompression operation. This positioning and fixing of the transparent film is then carried out when the outer surface 31 of the coating layer 3 is still hot, in particular with a temperature of approximately 170°C to 200°C. In such an implementation, under the action of the residual heat resulting from the thermocompression operation, the film undergoes at least partial melting and adheres to the outer surface 31 of the coating layer 3.Under these conditions, the implementation of the process is likely to eliminate the need for a possible additional heating step intended to optimize the adhesion of the protective layer 4 to the coating layer 3. The carbon footprint of the manufacturing process according to the invention is consequently reduced.

[0050] Of course, the invention is not limited to the embodiments described and shown in the accompanying drawings. Modifications remain possible, particularly with regard to the composition of the various elements or by substitution of technical equivalents, without departing from the scope of protection of the invention.

Claims

Demands

1. A vehicle interior trim panel component (1) comprising: - a rigid backing layer (2), this backing layer (2) comprising predominantly at least one thermoplastic, in particular of the polypropylene type, - a covering layer (3), of the non-woven textile type, superimposed, directly or indirectly, on the backing layer (2), this covering layer (3) comprising at least one blend of thermoplastic fibers, of the polypropylene or polyester type, according to a physicochemical composition different from that of the backing layer (2), characterized in that the blend of the covering layer (3) also comprises pieces of textiles (30) substantially arranged in the plane of the covering layer (3).

2. Part (1) according to claim 1, characterized in that the textile pieces (30) of the coating layer (3) are arranged so as to be at least partially superimposed on each other.

3. Part (1) according to any one of claims 1 or 2, characterized in that the textile pieces (30) of the coating layer (3) are arranged to be distributed over the entire covering surface of the coating layer (3).

4. Part (1) according to any one of claims 1 or 2, characterized in that the textile pieces (30) of the coating layer (3) are arranged to leave areas devoid of textile pieces (30) at certain points of the covering surface of the coating layer (3).

5. Part (1) according to any one of the preceding claims, characterized in that the material mixture of the coating layer (3) is made by combining, on the one hand, 5% to 15% of a mixture in identical or even similar proportions of co-extruded bi-component polypropylene and polyester fibers and, on the other hand, 20% to 40% of polypropylene fibers, the remainder of the material of the mixture being supplied by the textile parts (30) integrated into the coating layer (3).

6. Part (1) according to any one of the preceding claims, characterized in that the coating layer (3) has an average thickness of less than 10 millimeters.

7. Part (1) according to any one of the preceding claims, characterized in that the panel part (1) comprises an intermediate layer (6) positioned between the coating layer (3) and the support layer (2), this intermediate layer (6) being arranged to cover the entire surface of the support layer (2).

8. Part (1) according to claim 7, characterized in that the intermediate layer (6) comprises at least one mixture of thermoplastic fibers, of the polypropylene or polyester type, and shredded textile fibers.

9. Part (1) according to any one of the preceding claims, characterized in that the coating layer (3) comprises an outer surface (31), opposite the surface facing the support layer (2), which has at least one relief and / or a non-smooth arrangement.

10. Part (1) according to any one of the preceding claims, characterized in that the part (1) also comprises a protective layer (4) positioned on at least a part of the outer surface (31) of the coating layer (3), i.e. opposite the surface of the coating layer arranged opposite the support layer (2), this protective layer (4) being capable of being at least partly transparent or translucent.

11. A method for manufacturing a component (1) of a vehicle interior trim panel according to any one of claims 1 to 10, the method comprising at least: - a preparation phase for the coating layer (3), this preparation comprising at least one step of collecting and selecting textile pieces (30) intended for recycling, - a phase of assembling and fixing, directly or indirectly, the coating layer (3) to the support layer (2), characterized in that the preparation phase for the coating layer (3) also comprises: - a step of mixing textile pieces (30) with thermoplastic fibers, such as polypropylene and / or polyester, - a step of binding the mixture so as to obtain a non-woven textile type material, - a step of cutting the material to the desired dimensions so as to make at least part of the coating layer (3) of the piece (1).

12. A manufacturing process according to claim 11, characterized in that the step of mixing textile pieces (30) with thermoplastic fibers is carried out by air mixing.

13. A manufacturing process according to any one of claims 11 or 12, characterized in that the mixing binding step is carried out by heating and rolling and / or calendering the mixture.

14. A manufacturing process according to any one of claims 11 or 12, characterized in that, on the one hand, the recycled textile pieces (30) have dimensions of the order of 3 to 120 mm and, on the other hand, the thermoplastic fibers have dimensions of the order of 2 to 20 mm.

15. A manufacturing process according to any one of claims 11 and 14, characterized in that the assembly phase of the coating layer (3) on the support layer (2) involves: - a positioning step of the coating layer (3) in a mold, - a thermocompression operation.

16. A manufacturing method according to claim 15, characterized in that the method further comprises an overmolding operation of at least one additional element (5) by injection, this additional element (5) being capable of being an index, a fastening means, a clip, or even a rib.

17. A manufacturing method according to any one of claims 11 and 14, characterized in that the assembly phase of the coating layer (3) on the support layer (2) involves at least one material injection operation.

18. A manufacturing method according to any one of claims 11 and 14, characterized in that the assembly phase of the coating layer (3) onto the support layer (2) involves at least one bonding and / or sheathing operation using at least one adhesive material and / or glue.

19. A manufacturing method according to any one of claims 11 to 18, characterized in that the method further comprises a step of positioning and fixing a protective layer (4) on at least a part of the outer surface (31) of the coating layer (3), i.e. opposite the surface of the coating layer (3) arranged opposite the support layer (2).

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