Method for manufacturing a trim element having a visible surface with a metal pattern, and associated trim element

Abstract

The present invention relates to a method for manufacturing a vehicle trim element, the manufacturing method comprising the steps of: - providing at least one decorative element (22) 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 decorative element (22), the at least one decorative element (22) and the plastics material (26) mechanically binding to one another. The at least one decorative element (22) comprises a visible surface having a metal appearance, or the method comprises a step of coating the at least one decorative element (22) with metal after the step of introducing the plastics material (26).

Description

[0001] Method for manufacturing a visible surface trim element with a metallic pattern, and associated trim element

[0002] The present invention relates to a method for manufacturing a visible surface trim element with a metallic pattern, and an associated trim element.

[0003] We know of the production of a filling element in which a metallic coating is produced, for example by physical deposition of the coating by vapor phase or by chemical coating.

[0004] However, such a coating is then applied over a large area of ​​the trim element.

[0005] The aim of the invention is therefore to propose a method for manufacturing a trim element, having a visible surface, the method making it possible to obtain a trim element with one or more limited areas of metallic appearance, for example in the form of a pattern, on the visible surface.

[0006] 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:

[0007] - supply of a mold comprising a molding surface,

[0008] - provision of at least one decorative element on the molding surface according to a pattern,

[0009] - introduction into the mold of plastic material, the plastic material extending against the molding surface and at least one decorative element,

[0010] at least one decorative element and the plastic material mechanically bonded to each other,

[0011] in which at least one decorative element comprises a visible surface, the visible surface being arranged at least partially against the molding surface when supplying at least one decorative element, the visible surface having a metallic appearance during the supply step of at least one decorative element, or in which the process includes a step of coating at least one decorative element, after the plastic material introduction step, with a metallic coating.

[0012] The resulting trim element therefore has a metallic appearance on at least one decorative element, so as to have a metallic-looking pattern.

[0013] According to other advantageous aspects of the invention, the method comprises one or more of the following features, taken individually or in all technically possible combinations: - the at least one decorative element supplied comprises a main body, the main body forming the visible surface of the at least one decorative element and comprising metallic particles;

[0014] - the main body is made of thermoplastic material including metallic particles;

[0015] - at least one decorative element includes a main body made of thermoplastic material, more particularly comprising polypropylene or Acrylonitrile-Butabiene-Styrene;

[0016] - the coating step includes a physical vapor phase coating deposition step or a chemical coating step;

[0017] - the coating step includes the establishment of an electrical potential difference between at least one decorative element and the plastic material and / or a masking step of the plastic material and / or a step of removing the coating from the plastic material;

[0018] - the supply of at least one decorative element is carried out by additive manufacturing or by extrusion of molten granules;

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

[0020] - the plastic material is a thermoplastic material, more specifically polypropylene or Acrylonitrile-Butadiene-Styrene.

[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 step in supplying at least one decorative element in a first embodiment of the process according to the invention,

[0024] [Fig. 2] Figure 2 is a schematic representation of an example of a step for introducing the plastic material in the first embodiment of the process according to the invention,

[0025] [Fig. 3] Figure 3 is a schematic representation of an example of a trim assembly obtained by the first embodiment of the process according to the invention, and [Fig. 4] Figure 4 is a schematic representation of an example of a trim assembly obtained by a second embodiment of the process according to the invention. The invention relates to a method for manufacturing a vehicle trim element, the trim element having a visible face.

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

[0027] The process includes the following steps:

[0028] - provide a mold 10 comprising a molding surface 16,

[0029] - provide at least one decorative element 22 on the molding surface 16 according to a pattern, and

[0030] - introduce 10 of the plastic material 26 into the mold,

[0031] at least one decorative element 22 and the plastic material 26 mechanically bonded to each other.

[0032] The process further includes a step of hardening the plastic material and a step of removing the assembly comprising the hardened plastic material 26 and at least one decorative element 22 from the mold 10 after the hardening of the plastic material 26.

[0033] A first embodiment of the process according to the invention will now be described with reference to figures 1 to 3.

[0034] 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.

[0035] Mold 10 has a molding surface 16.

[0036] In at least one mold configuration, the molding surface 16 delimits a molding cavity 20.

[0037] The mold 10 also includes a material inlet 18.

[0038] The material inlet 18 opens into the molding cavity 20.

[0039] 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.

[0040] Each mold part 12, 14 includes 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.

[0041] In the open configuration, the mold parts 12, 14 are spaced apart. 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. Alternatively, mold 10 is a rotomolding mold or an injection and blow molding mold.

[0044] At least one decorative element 22 is provided, more particularly 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.

[0045] A schematic representation of an example of this step is shown in Figure 1.

[0046] The distribution of at least one decorative element 22 is carried out by additive manufacturing, more particularly by fused filament deposition (or FDM from the English Fused deposition modeling), or by extrusion of molten granules.

[0047] More particularly, at least one decorative element 22 is distributed by at least one nozzle 24 onto the molding surface 16, more particularly only onto a part of the portion of the molding surface defined by one of the mold parts, here the first mold part 12.

[0048] 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 pattern, to form at least one decorative element 22.

[0049] The material is, for example, heated upstream of the nozzle 24, so as to flow through the nozzle 24 onto the molding surface 16.

[0050] The material is a thermoplastic with a melting point, the material being heated to a temperature above said melting point upstream of the nozzle 24. 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 supply of at least one decorative element 22 is carried out in open configuration of the mold.

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

[0053] The height is, for example, between 0.2 mm and 0.5 mm.

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

[0055] The contact surface of the decorative element 22 with the molding surface 16 is, for example, less than 1 mm 2 .At least one decorative element 22 is made of a material suitable for bonding with the plastic material 26 introduced in a later stage.

[0056] At least one decorative element 22 includes, for example, a main body made of thermoplastic material, more particularly comprising polypropylene (PP) or Acrylonitrile-Butabiene-Styrene (ABS).

[0057] At least one decorative element 22 includes a visible surface 28.

[0058] The visible surface 28 is arranged at least partially against the molding surface 16 when at least one decorative element 22 is supplied.

[0059] More specifically, the visible surface 28 here corresponds to the entire surface of at least one decorative element 22 in contact with the molding surface 16.

[0060] In the first embodiment of the process of the invention, the visible surface 28 has a metallic appearance.

[0061] The main body here forms the visible surface 28.

[0062] More specifically, at least one decorative element 22 consists of the main body.

[0063] The main body comprises 30 metallic particles.

[0064] Here, the main body is made of thermoplastic material comprising 30 metallic particles. The 30 metallic particles can be, for example, particles of bronze, copper, brass, steel or iron.

[0065] Between the provision of at least one decorative element 22 and the introduction of the plastic material 26, the at least one decorative element is, for example, optionally, kept at temperature.

[0066] 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.

[0067] The material inlet 18 opens at the level of the molding surface 16, here delimited by a different part of the mold than the one on which at least one decorative element 22 has been distributed. Here, the material inlet 18 opens at the level of the portion of the molding surface 16 defined by the second part of the mold.

[0068] Plastic material 26 is a thermoplastic material, more specifically polypropylene or Acrylonitrile-Butabiene-Styrene.

[0069] The introduction of the plastic material is, for example, carried out in a closed configuration of the mold.

[0070] The plastic material 26 is introduced, so that the plastic material spreads against the molding surface 16 and at least one decorative element 22. During the introduction step, at least one decorative element 22 remains in contact with the molding surface 16, more particularly according to the pattern.

[0071] More specifically, the introduced plastic material plates at least one decorative element 22 against the molding surface 16.

[0072] During the introduction stage, the plastic material is heated to a temperature above its melting point.

[0073] More specifically, the plastic material is introduced in fluid form, here molten, so as to cover at least one texture element, and here also to fill the molding cavity 20.

[0074] The introduction of plastic material 26 into the mold here involves injecting the plastic material 26, in this case molten, into the mold cavity 20 delimited by the mold surface 16. 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.

[0075] 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 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.

[0076] 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.

[0077] The material inlet of the injection-blowing mold is designed for the injection of a gas, for example air.

[0078] 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.

[0079] More specifically, the preform is heated after its introduction so that it can be deformed by blow molding. The preform is then, for example, heated to a temperature between 170°C and 230°C. The introduction of the plastic material into the mold also includes the introduction of gas into the preform, so as to blow mold it.

[0080] The preform is then blown until the walls of the preform extend against the molding surface and cover at least one decorative element 22.

[0081] The hardening includes, for example, the cooling of the assembly formed from the hardened plastic material 26 and at least one decorative element 22, more particularly to 50°C.

[0082] The mold no longer heats up during the hardening stage.

[0083] After the hardening of the plastic material, the assembly formed of the hardened plastic material 26 and at least one decorative element 22 is then, for example, removed from the mold 10, more particularly from the molding cavity 20.

[0084] More specifically, the mold 10 is moved into the open position, the assembly formed of the hardened plastic material 26 and at least one decorative element 22 then being extracted from the mold 10 during or after the movement of the mold.

[0085] An example of this set is shown in Figure 3.

[0086] The plastic material is no longer malleable, so the assembly retains its shape. The at least one decorative element 22 and the plastic material 26 are mechanically bonded to each other, so as to become fixed together, during the plastic material introduction stage and / or during the hardening stage.

[0087] This forms a trim element.

[0088] At least one decorative element 22, more particularly the visible surface 28, is visible on a visible face 32 of the trim element.

[0089] The visible face 32 of the trim element therefore has a pattern with a metallic appearance, corresponding to at least one decorative element 22.

[0090] A second embodiment of the process according to the invention will now be described.

[0091] An example of a trim element 110 obtained by this second embodiment is shown in Figure 4.

[0092] Only the characteristics by which this second embodiment differs from the first embodiment will now be described.

[0093] In the second embodiment, the at least one decorative element 122 does not necessarily include a visible surface with a metallic appearance. Here, the at least one decorative element does not have a visible surface with a metallic appearance.

[0094] In particular, the main body does not necessarily include metallic particles. At least one decorative element 122 includes, more particularly is made of, a main body of thermoplastic material, for example polypropylene or Acrylonitrile-Butabiene-Styrene, here devoid of metallic particles.

[0095] The supply step, more specifically the distribution step, of at least one decorative element 122 is similar to that described in relation to the first embodiment.

[0096] The step of supplying the plastic material 126 is similar to that described in relation to the first embodiment.

[0097] Plastic material 126 is, for example, similar to that described in relation to the first embodiment.

[0098] The process according to the second embodiment further includes also a step of hardening the plastic material 126 and a step of removing the assembly formed of the plastic material 126 and at least one decorative element 122 from the mold, similarly to the first embodiment.

[0099] The process according to the second embodiment includes a step of coating at least one decorative element 122, after the step of introducing the plastic material 126, with a metallic coating 128.

[0100] The coating step is, for example, carried out after the mold removal step. The coating step includes the application of the coating to at least one decorative element, more particularly to at least the entire external surface of the decorative element 122 not covered by the plastic material 126.

[0101] The coating stage, more specifically the application of the coating, includes, for example, a physical vapor deposition (PVD) stage or a chemical coating stage.

[0102] The metallic coating 128 comprises, more specifically is made of, chromium.

[0103] The metallic coating 128 has a thickness less than or equal to 0.1 µm. After the coating step, the metallic coating 128 is present only on at least one decorative element 122, more particularly only on the surface of at least one decorative element 122 not covered by the plastic material 126.

[0104] The visible face 132 of the trim element then presents a pattern having a metallic appearance, corresponding to at least one decorative element 122.

[0105] The coating is applied, for example, in a localized manner on the surface of at least one decorative element 122 not covered by the plastic material. The coating is applied only on the surface of at least one decorative element 122 not covered by the plastic material 126.

[0106] The coating stage includes, for example, the establishment of an electrical potential difference between at least one decorative element and the plastic material, particularly during the application of the coating.

[0107] A localized charge is, for example, applied in a localized manner on at least one decorative element 122, so as to create a potential difference with the plastic material 126.

[0108] The charge is, for example, applied to at least one decorative element 122 upstream of its distribution, during its supply, or after its supply, up to and during the application of the coating.

[0109] During the application of the metallic coating, the metallic coating is attracted by the load applied to at least one decorative element 122, so that only at least one decorative element 122 is coated by the metallic coating 128.

[0110] This therefore makes it easy to achieve a targeted coating of the pattern formed by at least one decorative element 122, present on the visible surface 132 of the trim element 110.

[0111] Alternatively, the coating step includes a masking step of the plastic material 126, before the application of the coating 128.

[0112] A mask is attached, in a removable manner, to a surface of the plastic material 126 which is not to be coated, which may receive coating during the application of the coating.

[0113] The mask is, for example, fixed to the entire plastic material 126 in a continuous area including the surfaces of the decorative elements 122 not covered by the plastic material 126.

[0114] The coating is then applied to the surfaces of the decorative elements 122 not covered by the plastic material 126, for example over the entire continuous area.

[0115] The coating then partially covers the mask.

[0116] The coating step then includes the removal of the mask after the application of coating 128.

[0117] Thus, only the coating 128 on the surfaces of the decorative elements 122 not covered by the plastic material 126, which have not been covered by the mask, remains on the visible face 132 of the trim element 110.

[0118] Alternatively, the coating is applied to the surface of at least one decorative element 122 not covered by the plastic material 126, and possibly to a surface of plastic material 126, here not covered by a mask.

[0119] More specifically, in the case of multiple decorative elements 122, the application of the coating is carried out over a continuous area including the surfaces of the decorative elements 122 not covered by the plastic material 126.

[0120] The coating step includes, after the application of the coating, a step of removing the coating 128 from the plastic material 126, so that only the coating 128 remains on the surface of at least one decorative element 122 not covered by the plastic material 126.

[0121] The removal is, for example, carried out using a laser.

[0122] Following the coating stage, the metallic coating 128 is present only on at least one decorative element 122, so as to offer a metallic appearance of the pattern on the visible surface 132.

[0123] The process according to the invention therefore makes it possible to obtain a trim element with a visible face having a pattern having a metallic appearance.

[0124] The design is likely to be easily adapted by changing the location of the supply, more specifically the distribution, of at least one decorative element on the molding surface.

[0125] In a particular embodiment, not shown, the molding surface is partially delimited by a removable shell.

[0126] 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.

[0127] At least one decorative element is provided on the part of the molding surface formed by the removable shell.

[0128] This supply is, for example, carried out when the removable shell is separated from the mold part.

[0129] 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.

[0130] In one particular embodiment, the mold includes several copies of at least one removable shell.

[0131] 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 decoration element on a second copy of at least one removable shell for making a second filling element.

[0132] This allows, in particular, the distribution of at least one decorative element to be carried out in the background.

[0133] 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.

[0134] This makes it possible to produce trim elements using the process according to the invention more quickly.

[0135] In a particular embodiment, not shown, the process further includes a step of supplying a wall along at least a portion of at least one lateral surface of at least one decorative element 22, after supplying at least one decorative element 22 and before introducing the plastic material into the mold.

[0136] The lateral surface corresponds to one side of at least one decorative element arranged on the molding surface 16.

[0137] 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.

[0138] The presence of a wall against a lateral surface of the decorative element limits, or even avoids, the phenomenon of displacement of the material of the decorative element when introduced into the plastic mold, so that the contours of the pattern 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), - supply of at least one decorative element (22) on the molding surface (16) according to a pattern, - introduction into the mold (10) of plastic material (26), the plastic material (26) extending against the molding surface (16) and at least one decorative element (22), the at least one decorative element (22) and the plastic material (26) mechanically bonding to each other, wherein at least one decorative element (22) comprises a visible surface, the visible surface being arranged at least partially against the molding surface (16) when the at least one decorative element is supplied, the visible surface having a metallic appearance at the stage of supplying the at least one decorative element, or in which the process includes a step of coating at least one decorative element (22), after the step of introducing the plastic material (26), with a metallic coating.

2. A manufacturing method according to claim 1, wherein the at least one decorative element (22) supplied comprises a main body, the main body forming the visible surface of the at least one decorative element and comprising metallic particles.

3. A manufacturing method according to claim 2, wherein the main body is made of thermoplastic material comprising metallic particles.

4. A manufacturing method according to any one of claims 1 to 3, wherein at least one decorative element comprises a main body made of thermoplastic material, more particularly comprising polypropylene or Acrylonitrile-Butabiene-Styrene.

5. A manufacturing process according to any one of claims 1 to 4, wherein the coating step comprises a physical vapor phase coating deposition step or a chemical coating step.

6. A manufacturing method according to any one of claims 1 to 5, wherein the coating step comprises establishing an electrical potential difference between at least one decorative element and the plastic material and / or a step of masking the plastic material and / or a step of removing the coating from the plastic material.

7. A manufacturing method according to any one of claims 1 to 6, wherein the supply of at least one decorative element (22) is carried out by additive manufacturing or by extrusion of molten granules.

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

9. A manufacturing process according to any one of claims 1 to 8, wherein the plastic material is a thermoplastic material, more particularly polypropylene or Acrylonitrile-Butadiene-Styrene.

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

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