Method for manufacturing a trim element having a surface with imprints, and associated trim element

Abstract

The present invention relates to a method for manufacturing a vehicle trim element, the trim element having a visible face, the manufacturing method comprising the steps of: - arranging at least one textured plastics element on the moulding surface of a mould in accordance with a pattern, - introducing plastics material (26) into the mould such that the plastics material (26) extends against the moulding surface and the at least one textured element, - curing the plastics material (26), and - removing the at least one textured element from the plastics material (26) such that the at least one textured element leaves an imprint of the pattern on the plastics material (26). The invention further relates to an associated trim element.

Description

[0001] Method for manufacturing a surface-mounted filler element with indentations, and associated filler element

[0002] The present invention relates to a method for manufacturing a surface-textured filling element, and an associated filling element.

[0003] The trim element includes a visible surface with a three-dimensional texture.

[0004] This texturing is, for example, desired for aesthetic reasons.

[0005] One way to achieve such a textured visible surface is to produce the filler element in a mold with the desired relief, for example, through chemical or mechanical graining. However, this requires a separate mold for each desired texture: if the same part number exists with different textures on the visible face, then a mold must be created for each desired texture, which is complex, cumbersome, and expensive.

[0006] The aim of the invention is therefore to propose a manufacturing process for a trim element with a visible surface exhibiting a desired texture and simple to implement.

[0007] To this end, the invention relates to a method for manufacturing a vehicle trim element, the trim element having a visible face, the manufacturing method comprising the following steps:

[0008] - supply of a mold comprising a molding surface,

[0009] - arrangement of at least one plastic texture element on the molding surface according to a pattern,

[0010] - introduction into the plastic mold, the plastic material (26) extending against the molding surface and at least one textured element,

[0011] - hardening of the plastic material, and

[0012] - removal of at least one texture element from the plastic material, at least one texture element leaving an imprint of the pattern on the plastic material.

[0013] This allows for the creation of a filling element with the desired three-dimensional texture, particularly according to any desired pattern: indeed, it is sufficient to distribute at least one texture element according to the desired pattern of the impression. Furthermore, this does not require a special mold to achieve the texturing, as the mold has a molding cavity without said texturing, which is achieved by the presence of at least one texture element. According to other advantageous aspects of the invention, the method comprises one or more of the following features, taken individually or in any technically feasible combination:

[0014] - at least one texture element is made of a material that does not bond with the plastic material;

[0015] - at least one texture element is made of a material capable of dissolving in a solvent, for example made of polyvinyl alcohol, copolymer of butenediol and vinyl alcohol or high-impact polystyrene;

[0016] - the removal of at least one texture element from the plastic material includes washing the assembly including the hardened plastic material and the at least one texture element with the solvent, the at least one texture element being dissolved;

[0017] - the manufacturing process includes a step of removing the assembly comprising the hardened plastic material and at least one texture element from the mold after the hardening of the plastic material;

[0018] - the arrangement of at least one texture element is achieved by additive manufacturing or by extrusion of molten granules;

[0019] - the introduction of plastic material into the mold includes injecting the molten plastic material into a molding cavity delimited by the molding surface; and / or

[0020] - the mold comprises a plurality of mold parts, the mold parts being movable between them between an open mold configuration, in which the mold parts are spaced apart from each other, and a molding configuration, in which the mold parts delimit a molding cavity, the introduction of the plastic material being carried out in the molding configuration.

[0021] The invention also relates to a filling element obtained by a manufacturing process as defined above.

[0022] The invention will become clearer upon reading the following description, given solely by way of non-limiting example, and made with reference to the drawings in which:

[0023] [Fig. 1] Figure 1 is a schematic representation of an example of a distribution step of at least one texture element in an embodiment of the process according to the invention,

[0024] [Fig. 2] Figure 2 is a schematic representation of an example of a step of introducing the plastic material in an embodiment of the process according to the invention, [Fig. 3] Figure 3 is a schematic representation of an example of an assembly comprising the plastic material and at least one texture element, after hardening of the plastic material, in an embodiment of the process according to the invention, and [Fig. 4] Figure 4 is a schematic representation of an example of a filling assembly, after removal of at least one texture element, in an embodiment of the process according to the invention.

[0025] Steps of an example embodiment of the process according to the invention are shown in Figures 1 to 4.

[0026] The invention also relates to a filling element obtained by the manufacturing process according to the invention.

[0027] The process according to the invention is a process for manufacturing a vehicle trim element, the trim element having a visible face.

[0028] The process includes the following steps:

[0029] - provide a mold including a molding surface,

[0030] - arrange, more specifically distribute, at least one textured element on the molding surface according to a pattern,

[0031] - introduce plastic material into the mold,

[0032] - hardening of the plastic material, and

[0033] - remove at least one element of texture from the plastic material.

[0034] The process further includes a step of removing the assembly comprising the plastic material and at least one texture element from the mold after the hardening of the plastic material, and before the removal of at least one texture element from the plastic material.

[0035] An example of a mold 10 that can be used for the manufacturing process according to the invention is shown schematically in Figures 1 and 2.

[0036] Mold 10 has a molding surface 16.

[0037] In at least one mold configuration, the molding surface 16 delimits a molding cavity 20.

[0038] The mold 10 also includes a material inlet 18.

[0039] The material inlet 18 opens into the molding cavity 20.

[0040] The mold 10 includes, for example, here, a plurality of parts of mold 12, 14, here a first part of mold 12 and a second part of mold 14.

[0041] Each mold part 12, 14 comprises a portion of the molding surface 16. The mold parts 12, 14 are movable relative to each other between an open configuration and a molding configuration. In the open configuration, the mold parts 12, 14 are spaced apart from each other. The molding surface 16 is accessible.

[0042] In the molding configuration, the mold parts 12, 14 delimit the molding cavity 20. The mold parts 12, 14 extend against each other, so as to delimit said molding cavity.

[0043] Mold 10 is, for example, an injection mold, for example, for injection overmolding.

[0044] Alternatively, mold 10 is a rotomolding mold or an injection and blow molding mold.

[0045] At least one texture element 22, here plastic, is arranged, here distributed, on the molding surface 16 of the mold 10, more particularly here on the portion of the molding surface 16 delimited by the first part of the mold 12, more particularly only on a part of the portion of the molding surface 16 delimited by the first part of the mold 12.

[0046] A schematic representation of an example of this step is shown in Figure 1.

[0047] The distribution of at least one texture element 22 is achieved by additive manufacturing, more specifically by fused filament deposition (or FDM from the English Fused deposition modeling), or by extrusion of fused granules.

[0048] More specifically, at least one texture element 22 is distributed by a nozzle 24 onto the molding surface 16, more specifically only onto a part of the portion of the molding surface defined by one of the mold parts, here the first mold part 12.

[0049] The nozzle 24 is able to move in relation to the molding surface 16, here in relation to the portion of the molding surface delimited by the first part of the mold 12, so as to deposit material, more particularly according to a desired impression pattern(s).

[0050] The material is, for example, heated upstream of the nozzle 24, so that it flows through the nozzle 24 onto the molding surface 16. The material is, for example, heated to a temperature between 160°C and 300°C. The molding surface 16 is, for example, heated to a temperature between 20°C and 150°C.

[0051] The distribution of at least one texture element 22 is carried out in the open configuration of the mold.

[0052] At least one texture element 22 has a height, measured perpendicular to the molding surface 16.

[0053] The height is in accordance with the desired depth of the indentation. The height is, for example, between 0.05 mm and 1 mm.

[0054] At least one plastic texture element 22 is characterized by a localized and small contact surface on the molding surface 16.

[0055] The contact surface of the texture element 22 with the molding surface 16 is, for example, less than 1 mm 2 .

[0056] The process according to the invention is particularly advantageous for such a height because the deposition of the texture element takes place in a localized manner, which makes it possible to obtain a complex imprint pattern. At least one texture element 22 is made of a thermoplastic material.

[0057] At least one texture element 22 is made of a material that does not bond with the plastic material introduced in a later step.

[0058] At least one texture element 22 is, for example, made of a material capable of dissolving in a given solvent.

[0059] At least one texture element 22 is, for example, made of polyvinyl alcohol (or PVA from the English PolyVinyl Alcohol), of butenediol vinyl alcohol copolymer (or BVOH, from the English Butenediol Vinyl Alcohol Co-polymer) or of high impact polystyrene (or HIPS from the English High Impact Polystyrene).

[0060] At least one texture element 22 has, for example, a color identical to the color of the plastic material.

[0061] Alternatively, at least one texture element 22 may, for example, have a different color than the plastic material. This increases the contrast between at least one texture element 22 and the plastic material and facilitates the removal of at least one texture element 22 in a subsequent step.

[0062] The mold is, for example, heated between the arrangement of at least one texture element 22 and the introduction of the plastic material.

[0063] The mold is then, for example, moved into the molding configuration. The plastic material 26 is then introduced into the mold 10, more specifically into the molding cavity 20, here through the material inlet 18.

[0064] The material inlet 18 opens at the molding surface 16, here delimited by a different part of the mold than the one on which at least one texture element 22 has been distributed. Here, the material inlet 18 opens at the portion of the molding surface 16 defined by the second part of the mold.

[0065] The introduction of the plastic material is, for example, carried out in a closed configuration of the mold.

[0066] The plastic material is introduced so that the plastic material spreads against the molding surface and at least one texture element. More specifically, the plastic material is in fluid form, here molten, and is introduced so as to cover at least one texture element, and here also to fill the molding cavity.

[0067] During the introduction of the plastic material, at least one texture element 22 remains in contact with the molding surface 16. More particularly, the plastic material exerts a force pushing, at least in part, the at least one texture element 22 against the molding surface 16.

[0068] The introduction of plastic material into the mold involves injecting the molten plastic into the mold cavity defined by the mold surface. This introduction corresponds, for example, to injection molding. The material introduced by injection molding has, for example, a temperature between 160°C and 300°C.

[0069] Plastic material is a thermoplastic material that does not bond with the material of at least one texture element 22.

[0070] The plastic material is, for example, polypropylene (PP).

[0071] Alternatively, the plastic material is acrylonitrile butadiene styrene (ABS), polycarbonate (PC), polymethyl methacrylate (PMMA), a mixture of polycarbonate and acrylonitrile butadiene styrene (PC ABS); a mixture of polypropylene and glass fibers (PP GF); a mixture of polypropylene and natural fibers (NF PP).

[0072] In an alternative embodiment to injection molding as described above, the introduction of plastic material into the mold includes a step of introducing plastic material into the mold cavity via a material inlet, the mold being a rotomolding mold. The introduction of plastic material into the mold then further includes setting the mold in motion, more specifically rotating the mold, to distribute the introduced plastic material over the molding surface and cover at least one texture element. More specifically, the plastic material is introduced in powder form. Thus, before rotating the mold, the plastic powder is heated to obtain a fluid plastic material that is evenly distributed over the molding surface.

[0073] In an alternative embodiment to injection as described above and to rotomolding, the introduction into the mold of plastic material includes a step of introducing a preform into an injection-blowing mold, the preform being made in the plastic material.

[0074] The material inlet of the injection-blowing mold is designed for the injection of a gas, for example air. The preform is arranged so that the neck of the preform is held at the level of the material inlet, so that the material inlet is able to inject the gas into the preform, so as to blow the preform.

[0075] More specifically, the preform is heated after its introduction, so as to be deformable by blowing. The preform is then, for example, heated to a temperature between 170°C and 230°C.

[0076] The introduction of plastic material into the mold then also includes the introduction of gas into the preform, so as to blow the preform.

[0077] The preform is then blown until the walls of the preform extend against the molding surface and cover at least one texture element 22.

[0078] The hardening includes, for example, the cooling of the assembly formed by the plastic material 26 and at least one texture element 22, more particularly down to 50°C.

[0079] The mold no longer heats up during the hardening stage.

[0080] After the hardening of the plastic material, the assembly formed from the hardened plastic material 26 and at least one texture element 22 is then, for example, removed from the mold 10, more particularly from the molding cavity 20.

[0081] More specifically, the mold 10 is moved into the open position, the assembly formed of the hardened plastic material 26 and at least one texture element 22 being removed from the mold 10 during or after the move into the open position.

[0082] An example of this set is shown in Figure 3.

[0083] The plastic material is no longer malleable, so the assembly retains its shape. At least one texture element 22 is then removed from the hardened plastic material 26, so that at least one texture element 22 leaves at least one imprint 28 of the pattern on the hardened plastic material 26.

[0084] At least one impression 28 forms one or more recessed areas in relation to a surface 30 corresponding to the complement of the molding surface 16.

[0085] The removal of at least one texture element 22 from the plastic material 26 includes, for example, washing the assembly comprising the plastic material and the at least one texture element with the given solvent, so as to dissolve the at least one texture element 22.

[0086] The given solvent is, for example, water.

[0087] In an alternative embodiment, the removal of at least one texture element 22 from the plastic material 26 includes, for example, the mechanical removal, for example by disintegration or peeling, of at least one texture element from the hardened plastic material. This is, for example, achieved by mechanical action on the at least one texture element.

[0088] Since at least one texture element 22 is made of a material that does not bond with the plastic material, at least one texture element 22 then separates from the hardened plastic material.

[0089] Alternatively, the removal of at least one texture element 22 from the plastic material 26 includes, for example, the melting of at least one texture element 22.

[0090] At least one texture element 22 is, for example, made of a material with a melting point lower, for example at least 50°C, than the melting point of the plastic material.

[0091] The removal of at least one texture element 22 from the plastic material 26 then includes, for example, heating the assembly formed from the hardened plastic material and at least one texture element 22 to a temperature between the melting temperature of at least one texture element and the melting temperature of the plastic material, so that the plastic material remains solid, and at least one texture element 22 melts.

[0092] The removal of at least one texture element 22 from the plastic material 26 then includes the removal of at least one melted texture element 22.

[0093] Alternatively, the removal of at least one texture element 22 from the plastic material 26 includes, for example, vibrating the assembly formed from the hardened plastic material 26 and the at least one texture element 22, so as to dissociate the at least one texture element 22 and the hardened plastic material 26, i.e. that the at least one texture element 22 separates from the hardened plastic material 26.

[0094] The hardened plastic material 26 without at least one texture element 22 then forms the filling element, or at least part of the filling element.

[0095] At least one texture element 22 leaves one or more imprints at the location(s) where it / they was / were placed, more particularly on the surface 30.

[0096] Surface 30 forms a visible face of the trim element, so that it has a texture corresponding to the imprints.

[0097] An example of a trim element obtained according to the process of the invention is shown in Figure 4.

[0098] In a particular embodiment, not shown, the molding surface is partially delimited by a removable shell.

[0099] More specifically, the mold includes at least one removable shell capable of being reversibly attached to a part of the mold, so that the removable shell forms part of the molding surface. At least one decorative element and at least one texture element 22 are distributed on the part of the molding surface formed by the removable shell.

[0100] This distribution is, for example, achieved when the removable shell is separated from the mold part.

[0101] Then, the removable shell is attached to the mold part before the introduction of the plastic material, more specifically so that the removable shell partially delimits the molding cavity during introduction.

[0102] In one particular embodiment, the mold includes several copies of at least one removable shell.

[0103] The process then includes, for example, simultaneously a step of making a first filling element in the mold equipped with a first copy of at least one removable shell, for example the introduction of plastic material into the mold, and the distribution of at least one texture element 22 on a second copy of at least one removable shell for making a second filling element.

[0104] This allows, in particular, the distribution of at least one texture element 22 to be carried out in hidden time.

[0105] As soon as the first filling element is extracted from the mold fitted with the first copy of at least one removable shell, the second copy of at least one removable shell is fixed to the mold part, so as to equip the mold with this second copy of at least one removable shell.

[0106] This makes it possible to produce trim elements using the process according to the invention more quickly.

[0107] In a particular embodiment, not shown, the process further includes a step of distributing a wall along at least a portion of at least one lateral surface of at least one texture element 22, after the distribution of at least one texture element 22 and before the introduction into the mold of the plastic material.

[0108] The lateral surface corresponds to one side of at least one texture element arranged on the molding surface 16.

[0109] The wall is made of the same material as the introduced plastic. The wall is, for example, produced by additive manufacturing, more specifically by fused deposition modeling (FDM), or by extrusion of molten granules.

[0110] The presence of a wall against a lateral surface of the texture element limits, or even avoids, the phenomenon of displacement of the material of the texture element when introduced into the plastic mold, so that the contours of the resulting impression are particularly sharp.

Claims

DEMANDS 1. A method for manufacturing a vehicle trim element, the trim element having a visible face, the manufacturing process comprising the following steps: - supply of a mold (10) comprising a molding surface (16), - arrangement of at least one plastic texture element (22) on the molding surface (16) according to a pattern, - introduction of the plastic material (26) into the mold (10), the plastic material (26) extending against the molding surface (16) and at least one texture element (22), - hardening of the plastic material (26), and - removal of at least one texture element (22) from the plastic material (26), the at least one texture element (22) leaving an imprint of the pattern on the plastic material (26).

2. Manufacturing method according to claim 1, wherein at least one texture element (22) is made of a material not bonding with the plastic material (26).

3. A manufacturing method according to claim 1 or 2, wherein at least one texture element (22) is made of a material capable of dissolving in a solvent, for example made of polyvinyl alcohol, butenediol-vinyl alcohol copolymer or high-impact polystyrene.

4. A method according to claim 3, wherein the removal of at least one texture element (22) from the plastic material (26) comprises washing the assembly comprising the hardened plastic material (26) and the at least one texture element (22) with the solvent, the at least one texture element (22) being dissolved.

5. A manufacturing method according to any one of claims 1 to 4, comprising a step of removing the assembly comprising the hardened plastic material (26) and at least one texture element (22) from the mold (10) after the hardening of the plastic material (26).

6. A manufacturing method according to any one of claims 1 to 5, wherein the arrangement of at least one texture element (22) is achieved by additive manufacturing or by extrusion of molten granules.

7. A method according to any one of claims 1 to 6, wherein the introduction into the mold (10) of plastic material (26) comprises an injection of the molten plastic material into a molding cavity (20) delimited by the molding surface (16).

8. A method according to any one of claims 1 to 7, wherein the mold (10) comprises a plurality of mold parts (12, 14), the mold parts (12, 14) being movable relative to each other between an open configuration of the mold (10), in which the mold parts (12, 14) are spaced apart from each other, and a molding configuration of the mold (10), in which the mold parts (12, 14) delimit a molding cavity (20), the introduction of the plastic material (26) being carried out in the molding configuration of the mold (10).

9. Filling element obtained by a manufacturing process according to any one of claims 1 to 8.

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