BE1004210A3 - Element lining for motor vehicles and manufacturing. - Google Patents

Abstract

Upholstery element for use in a motor vehicle, characterized in that it comprises a covering sheet (12) having a surface having an embossed design, a first foam body (14) disposed on the other surface the cover sheet, a first component (16) being partially embedded in this first foam body; a second foam body (18) disposed on this other surface and / or on the first foam body, a second component (20) being partially embedded in this second foam body; the cover sheet, the first foam body and the second foam body being made in one piece in the form of a unitary construction.

Description

       

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  "Trim element for motor vehicle and its manufacture".



   The present invention relates to a lining element or interior lining, usable in a motor vehicle and comprising a unitary assembly comprising a covering sheet, an instrument panel, and a foam body, the invention also relating to a method and apparatus for manufacturing such a packing element.



   The trim elements used as interior trim and which include a motor vehicle instrument panel are mostly grained on their exterior surface to give a realistic appearance of leather. More specifically, a synthetic resin trim element is embossed to give its outer side the leather look that makes this trim element rich and sophisticated. To make such a grainy filling element, soft to the touch, the filling element comprises a composite sheet constituted by a sheet of vinyl chloride foam applied as a damping layer to a vinyl chloride sheet simulating leather. .



   In general, two methods of manufacturing grained packing elements for automobiles have been widely adopted. According to the first method, a cover sheet which is embossed on its outer surface is softened by heat and held against a pressure molding element of a molding device, and a core element coated with an adhesive on the surface intended to adhere to the cover sheet is held against a pressure molding element. Then, the die-casting elements are pressed against each other to apply to the cover sheet and shape the cover sheet and the core member to a desired shape, thereby completing the filling.

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   In the second method, a cover sheet which has been softened by heat is drawn under vacuum to an embossing mold element of a molding device. The embossing mold member is in the form of a porous electroformed mold member. Next, an adhesive coated core held against another mold member is pressed against the cover sheet which has been attracted to the embossing mold member, thereby producing a packing member.



   If a trim element comprising a motor vehicle instrument panel is to be manufactured by these traditional methods, as the trim element to be manufactured is large and of complex shape, this trim element must be shaped in two or three separate sections and then these formed sections must be combined. The entire manufacturing process is complicated and requires a number of steps because two or three separate sections must be formed first to form a single packing element.



   Another problem is that, when the separate sections formed are joined, the lines along which they are joined remain visible on the outer surface of the packing member. As a result, the finished packing element does not give the impression of a unitary body and is of a poor appearance because of the steps or surface irregularities which exist along the joint lines. Since the trim element consists of joined sections, the overall rigidity of the trim element is relatively poor and this trim element tends to make noise when the motor vehicle is in motion. The packing member is also heavy since the core member is used to reinforce the cover sheet.



   Various parts, such as conduits, boxes, etc., are attached to the packing element made by traditional methods. The overall assembly is therefore less resistant to creep or elongation. Consequently, after a certain period of use, the packing element becomes less rich and less sophisticated. In addition, the overall package

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 cannot be easily mounted so that the entire manufacturing process is of low efficiency.



   The cover sheet used with the instrument panel is of a very large and complex shape. As a result, it is difficult to graze the cover sheet uniformly over its entire surface, and it is difficult to remove the embossed cover sheet from the set of printing molds.



   A main object of the present invention is to provide a trim element usable in a motor vehicle, this trim element can be manufactured in the form of a unitary body in its entirety, and to provide an efficient manufacturing method and system. of such a packing element, while allowing various parts to be fixed to it effectively.



   Another object of the present invention is to provide a trim element usable in a motor vehicle, comprising a cover sheet having a surface having an embossed design, a first foam body disposed on the other surface of the cover sheet , a first component being partially embedded in the first foam body, and a second foam body disposed on the other surface and / or on the first foam body, a second component being partially embedded in this second foam body, the cover sheet, the first foam body and the second foam body being made in one piece in the form of a unitary construction.



   Another object of the present invention is to provide a packing element in which the first component consists of a magnetic metallic element, and the second component is made of a resin material.



   Another object of the present invention is to provide a packing element in which the first and second foam bodies are each made of a hard urethane foam resin.



   Yet another object of the present invention is to provide a packing element in which the cover sheet is in the form of a composite sheet comprising a sheet

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 resin imitating leather and a polyolefin foam sheet, the sheet imitating leather and the foam sheet being superimposed.



   Yet another object of the present invention is to provide a trim element usable in a motor vehicle, comprising a cover sheet of synthetic resin, a first foam body disposed on the cover sheet and having a positioning element for placing a component, and a second foam body in which the component placed by the positioning element of the first foam body is at least partially embedded, the cover sheet, the first foam body and the second body in foam being made in one piece in the form of a unitary construction.



   Another object of the present invention is to provide a packing element further comprising a seal element interposed between the component and the positioning element of the first foam body.



   Yet another object of the present invention is to provide a packing element in which the joint element consists of an elastic element.



   Another object of the present invention is to provide a method of manufacturing a trim element usable in a motor vehicle, comprising the following phases: the production of a cover sheet of a shape complementary to that of the filling element and having a surface having an embossed design, forming the first foam body on the cover sheet with a first component disposed on this cover sheet and partially embedded in the first foam body, and forming a second foam body on the cover sheet and / or on the first foam body, a second component being disposed and partially embedded in the second foam body.



   Another object of the present invention is to provide the abovementioned method further comprising the phase of removal by blowing of a separating agent, from the first foam body after formation thereof.

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   Yet another object of the present invention is to provide the abovementioned process further comprising the deburring phase of the second foam body after it has been formed.



   Yet another object of the present invention is to provide the above method in which the first component is made of a magnetic metallic material, the first foam body being formed by a first forming device comprising an upper molding die and a die lower molding, the first component being attracted magnetically to the upper molding die by a magnet, the cover sheet being attracted to the lower molding die by suction means creating a vacuum.



   Another object of the present invention is to provide the above method in which the second component is made of a resin material.



   Yet another object of the present invention is to provide the process in question, in which the first foam body is formed in one piece with a rib and / or a fastening base for positioning the second component when the first body foam is formed.



   Another object of the present invention is to provide the above method in which the first and second foam bodies are each made of a hard urethane foam resin.



   Yet another object of the present invention is to provide the above method in which the cover sheet is in the form of a composite sheet comprising a resin sheet imitating leather and a sheet of polyolefin foam, the sheet imitating leather and the foam sheet being superimposed.



   An object of the present invention is also to provide a method of manufacturing a trim element usable in a motor vehicle, comprising the following phases: the production of a cover sheet of a shape complementary to that of the filling element and comprising a surface having an embossed design, the formation of a first foam body on the cover sheet, this first foam body comprising

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 a positioning element intended for the positioning of a component, and the formation of a second foam body, the component placed by the positioning element being at least partially embedded in this body.



   Another object of the present invention is to provide the above method in which a seal element is provided on the positioning element of the first foam body.



   Yet another object of the present invention is to provide the above method in which the first foam body and / or the second foam body are made of a urethane foam resin.



   Yet another object of the present invention is to provide a method of manufacturing a trim element usable in a motor vehicle, comprising the following phases: the forming of a cover sheet of a predetermined shape by pressing a sheet blank between a first fixed molding die and a second movable molding die supported on a die to be stamped, maintaining an exposed end of the cover sheet in the pressed state between the first and second die molding, gripping means being mounted on the chassis sheep which is movable between the first and second molding dies, elevating the stamping sheep and the chassis sheep so that the stamping sheep is moved to a lower speed than the chassis sheep,

   to thereby separate the cover sheet from the second molding die, and mounting a component and a foam body on this cover sheet.



   Yet another object of the present invention is to provide a method of manufacturing a packing element usable in a motor vehicle, comprising the following phases: the pressure of a preheated blank between a first and a second molding die, the supply of pressurized air to the blank by the first mold or the second mold, and, after a predetermined period of time, the attraction of the blank by the second mold or the first mold,

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 to thus conform the blank into a cover sheet, and mounting a component and a foam body on this cover sheet.



   Yet another object of the present invention is to provide the abovementioned method further comprising the phase of transferring a predetermined pattern to a surface of the blank when the latter is shaped into the covering sheet.



   Another additional object of the present invention is to provide the above method, in which the blank consists of a laminated body of synthetic resin.



   Another object of the present invention is to provide a method of manufacturing a lining element usable in a motor vehicle comprising the following phases: the forming of a covering sheet of a shape complementary to that of the element of filling and comprising a surface having an embossed design, the positioning of the covering sheet in a set of molding dies comprising a cavity, the pouring of a foam resin into the cavity of the set of molding dies , bringing the cover sheet into contact with a shaping element of a surface forming the product of the set of molding dies, which defines the cavity, under a pressure produced by the foam resin when it is transformed into foam,

   to thereby produce a local shape of the cover sheet with the forming member, and adding a configuration complementary to that of the forming member to the covering sheet when the foam resin is cured.



   Another object of the present invention is to provide the above method in which the shaping element comprises a sliding core intended to add a cavity as a configuration to the covering sheet.



   A further object of the present invention is to provide the above method in which the shaping element comprises a cavity intended to add a patch as a configuration to the covering sheet.

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   Yet another object of the present invention is to provide a system for manufacturing a trim element usable in a motor vehicle, comprising a covering sheet forming device, intended to conform a covering sheet of a predetermined shape. by pressing a sheet blank between a first and a second molding die, the device for forming the covering sheet comprising a fixed plate supporting the first molding die, a vertically displaceable die for supporting the second die molding, a chassis sheep vertically movable between the fixed plate and the die for stamping,

   and gripping means for gripping an exposed end of the cover sheet when the first and second molding dies are brought together to press the sheet blank.



   Yet another object of the present invention is to provide the above-mentioned system, in which the gripping means consist of a series of clamping mechanisms each comprising a fixed clamping arm and a clamping arm movable relative to the fixed clamping arm. , the fixed and movable clamping arms having ends intended to grip the covering sheet, the clamping mechanisms being arranged opposite the first and second molding die and being movable towards and away from them .



   Another object of the present invention is to provide the above system, in which the chassis sheep comprises first rails extending horizontally and second rails connected to the first and extending outside the sheet forming device. covering, this system further comprising a loading trolley intended for loading the sheet blank and a movable unloading trolley along the first rails for discharging the covering sheet which is separated from the first and second molding die, the loading and unloading carriages being movable back and forth towards and away from the covering sheet forming device along the first rails.



   Yet another object of the present invention is to provide the above system further comprising main-

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 holding the configuration on the unloading cart to prevent the cover sheet from being deformed when separated from the first and second molding dies.



   Yet another object of the present invention is to provide a system for manufacturing a lining element usable in a motor vehicle, comprising a covering sheet forming device, intended to conform a covering sheet by pressing, put under pressure and attraction of a sheet blank between a first and a second molding die, each of these first and second molding dies comprising a first porous layer having a multitude of very small holes and receiving temperature control conduits, a second porous layer having a multitude of very small holes and attached as a reinforcing layer to the above-mentioned first porous layer,

   at least one of the first and second molding dies comprising a porous electroformed body disposed on the first porous layer.



   Another object of the present invention is to provide the above-mentioned system further comprising a pressure tank intended for pressurizing the sheet blank and a vacuum tank intended to attract the sheet blank under the effect of the vacuum.



   Yet another object of the present invention is to provide the above system in which the porous electroformed body has a grainy surface giving a leather appearance.



   A further object of the present invention is to provide a system for manufacturing a trim element usable in a motor vehicle, comprising a covering sheet positioning device for the installation of such a covering sheet. a predetermined shape in a set of molding dies to form a foam body in one piece with the cover sheet, this cover sheet positioning device comprising a frame and a series of pressure elements supported on the frame and of a shape complementary to different zones of all of the molding dies, with a view to pressing the covering sheet against these

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 different areas of all the molding dies.



   Yet another object of the present invention is to provide the aforementioned system in which the frame comprises a resin pipe, the covering sheet positioning device further comprising a profiled element of a shape essentially complementary to that of the assembly molding dies, the pressure elements being supported on the profiled element.



   Yet another object of the present invention is to provide the above system in which each of the pressure elements is made of a urethane elastomer.



   Another object of the present invention is to provide the above-mentioned system in which the profiled element comprises a skeleton of a shape essentially complementary to that of the cover sheet, the device for positioning the cover sheet further comprising pipes of resin support interconnecting the profiled element and the chassis.



   Yet another object of the present invention is to provide the above-mentioned system in which the profiled element is of a shape essentially complementary to that of the reverse side of the cover sheet, the profiled element and the frame being directly joined together. to each other.



   Yet another object of the present invention is to provide the above system in which the profiled element has an opening for discharging air from the area between the profiled element and the cover sheet.



   Another object of the present invention is to provide the aforementioned system in which each of the pressure elements comprises suction means for attracting the covering sheet under the effect of the vacuum.



   A further object of the present invention is to provide the above system in which the suction means comprise a first pipe attached to a vacuum pump, and a second pipe having an end communicating with a suction hole formed in each element of pressure, while the other end is connected to the first conduit.

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   An additional object of the present invention is to provide the above system further comprising a layer of porous resin interposed between the suction hole and the second conduit.



   The aforementioned aims, characteristics and advantages of the present invention as well as others will emerge from the following description which is given with reference to the appended drawings which illustrate by way of examples various preferred forms of implementation of the present invention.



   Figures la to lc are perspective views of a trim element usable in a motor vehicle according to the present invention.



   Figures 2a to 2d are cross-sectional views illustrating phases of the manufacture of the packing element illustrated in Figures la to le.



   Figure 3 is a diagram illustrating the phases of a manufacturing process according to the present invention.



   Figure 4 is a front elevational view of a device for forming a cover sheet.



   FIG. 5 is a front elevation view of the device for forming a cover sheet illustrated in FIG. 4.



   Figure 6 is a front elevational view of the cover sheet forming device, illustrating a state in which a formed cover sheet is removed from the cover sheet forming device.



   Figure 7 is a side elevational view of the cover sheet former.



   Figure 8a is a vertical sectional view of a set of molds used in the cover sheet former.



   Figure 8b is an enlarged sectional view illustrating the circled portion H of Figure 8a.



   Figure 8c is an enlarged partial sectional view of a porous electroformed body.



   Figure 9 is a partial perspective view

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 of product gripping means belonging to the covering sheet forming device.



   FIG. 10 is a side elevational view, partially in section, of the gripping means illustrated in FIG. 9.



   Figure 11 is a side elevational view, partially in section, of the cover sheet forming device, a loading device and a heating device which are installed in combination with each other.



   Figure 12 is a plan view of the loading cart.



   Figure 13 is a partial side elevational view of the loading cart.



   Figure 14 is a view of the rails for discharging a cover sheet from the cover sheet former, and also from an discharge cart.



   Figure 15 is a plan view of the unloading cart.



   Figure 16 is a side elevational view of a device for discharging a cover sheet.



   Figure 17 is a vertical sectional view of a first forming device used in the first foaming phase.



   Figure 18 is a perspective view of a device for the establishment of a cover sheet.



   Figure 19 is a vertical sectional view of the cover sheet positioning device.



   Figure 20 is a vertical sectional view of a second forming device used in a second foaming step.



   Figures 21a to 21d are views illustrating the phases of a process for forming a cover sheet.



   Figure 22 is a block diagram of the cover sheet forming process.



   Figure 23 is a perspective view of a device for the establishment of a cover sheet according to another embodiment of the present invention.

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   Figure 24 is a rear elevational view of the cover sheet positioning device illustrated in Figure 23.



   Figure 25 is a vertical sectional view of the cover sheet positioning device illustrated in Figure 23.



   FIG. 26 is an enlarged partial sectional view of part of the covering sheet positioning device illustrated in FIG. 25.



   Figure 27 is a sectional view of a trim element for a motor vehicle according to another embodiment of the present invention.



   Figure 28 is a vertical sectional view of a first forming device used in the first foaming phase of a manufacturing process for the packing element illustrated in Figure 27.



   Figure 29 is a vertical sectional view of a second forming device used in a second foaming step of the manufacturing process of the packing element illustrated in Figure 27.



   Figures 30a and 30b are views in vertical section illustrating the method of manufacturing a trim element for a motor vehicle according to another embodiment of the present invention.



   Figure 31 is a sectional view of a trim element for a motor vehicle according to yet another embodiment of the present invention.



   Figure 32 is a vertical section view of a forming device used for the manufacture of the packing element illustrated in Figure 31.



   Figs 33a to 33d are enlarged partial sectional views illustrating the phases of adding a hollow shape using a sliding core in the forming device illustrated in Figure 32.

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   Figures 34a and 34b are partial sectional views illustrating the phases of the addition of a hollowed shape using a cavity existing in a forming surface of a female molding element of the forming device illustrated in Figure 32.



   Figures la, Ib, le and 2d illustrate a trim element, generally designated by 10, and intended to be used as an interior trim in a motor vehicle. As illustrated in FIG. 2d, the lining element 10 comprises a covering sheet 12 which is embossed or grained to give it a leather appearance, a first foam body 14 disposed on the rear side of the covering sheet 12, a first component 16 molded in the first foam body 14, a second foam body 18 disposed on the first foam body 14 and / or on the cover sheet 12, and a second component 20 molded in the second foam body 18 .



   As illustrated in FIG. 1a, the packing element 10 comprises an area A for the attachment of an instrument panel, this area being provided on the left side and having a configuration of curved appearance, an area B for mounting the steering wheel, this zone being situated below the zone A for mounting the instrument panel, a storage box C disposed essentially centrally on the lining element 10 and shaped to contain an air conditioning unit, etc. , and a glove box D, arranged on the lower right side of the lining element 10 and comprising a cover which can be opened and closed.



   The cover plate 12 is in the form of a composite sheet comprising a sheet forming a leather of polyvinyl chloride or the like and a sheet of polyolefin foam, the sheet forming a leather and the sheet of foam adhering to each other. . The first and second foam bodies 14,18 are made of a hard urethane foam resin.



   As illustrated in FIG. 1b, the first component 16 comprises several supports 22 made of a magnetic metallic material, for example of a steel sheet, the supports 22 serving as reinforcements for the lining element 10. As illustrated by

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 Figure 1a, the second component 20 comprises a rear instrument box 24, a clock case 26 and a lateral duct 28, which are all made of a resin material.



   The packing element 10 is manufactured according to the steps which are schematically illustrated in FIG. 3. Various devices of a manufacturing system will be described below, which are used in the steps illustrated in FIG. 3.



   Figures 4 to 7 illustrate a device 30 for forming a cover sheet in a step of molding a cover sheet. The covering sheet forming device 30 comprises a lower plate 32, four uprights 34a to 34d arranged vertically at the corners of the lower plate 32, and an upper plate 36 fixed to the upper ends of the guide uprights 34a to 34d.



   A lower die base 38 is fixedly mounted on the lower plate 32, and a first molding die 40 is fixedly mounted as a male element or punch on the lower die base 38. A stamping sheep 42 , which is vertically movable while it is guided by the uprights 34a to 34d is arranged below the upper plate 36.



   The stamping sheep 42 is connected to a piston rod 43a of a hydraulic die clamping cylinder 43 mounted on the upper plate 36. A second molding die 46 serving as a female part is fixed to the lower surface of the stamping sheep 42, a plate 44 being interposed between them. The first molding die 40 has a surface for forming a convex product, and the second molding die 46 has a concave product forming surface. The convex and concave forming surfaces of product jointly deform a single sheet S (Figure 4) to give it a predetermined configuration, that is to say corresponding to the cover sheet 12 of a trim element for a motor vehicle. , comprising an instrument panel.

   The unitary sheet S is loaded into the cover sheet former 30 after it has been heated by a heating device, which will be described later.

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   A reservoir 48 containing pressurized air is disposed in the lower plate 32. The reservoir 48 is supplied with pressurized air from a source of pressurized air and it supplies this pressurized air to the first molding die 40 by a pressurized air conduit 48a connected to the reservoir 48. A vacuum reservoir 50, connected to a vacuum pump, is disposed in the upper plate 36 and also connected to the second molding die 46 by a vacuum conduit 50a. When the vacuum pump is turned on, a vacuum is created in the second molding die 46 through the vacuum tank 50 and the vacuum pipe 50a to thereby attract the unit sheet S to the second molding die 46.



   Figure 8a illustrates the first and second molding dies 40, 46 which are approximated to each other. The convex and concave forming surfaces of the first and second molding dies 40, 46 are essentially complementary to each other. The second molding die 46 comprises strongly inclined surface parts 52a, 52b (which will be called hereinafter "" hollowed out surface parts ") each comprising an interval g.



   Figure 8b shows on an enlarged scale an area circled H in Figure 8a. As illustrated in FIG. 8b, the first molding die 40 comprises a porous layer 54 having a multitude of very small holes and serving as a reinforcing body, and a porous layer 58 receiving conduits 56 for adjusting the temperatures. The second molding die 46 comprises a porous layer 60 having a multitude of very small holes and serving as a reinforcing body, a porous layer 64 intended to receive conduits 62 for adjusting the temperatures, and a porous body 68 connected to the layer porous 64 and having an embossing or printing surface 66. The porous electroformed body 68 is placed on the porous layer 64, and there is a space K between the porous layer 58 and the porous electroformed body 68.

   The space K is of a dimension slightly less than the thickness of the unitary sheet S to be conformed. Each of the porous layers 54, 60 comprises

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 EMI17.1
 m muttiMB [fe? little ones? ? ne ma 10 muniBE mMs
 EMI17.2
 by a thermosetting resin, ventilation holes or interstices being defined between the glass beads 70. The structure of such a porous layer is described in detail in Japanese patent publication No. 61 (1986) -272126.



   Each of the 58.64 porous layers attached
 EMI17.3
 to the corresponding porous layers 54, 60 and receiving the temperature regulation conduits 56, 62 is composed of a multitude of steel balls 72 partially joined together by a thermosetting synthetic resin, a large number of ventilation holes or interstices being defined between the steel balls 72. The construction of such a porous layer is also described in detail in Japanese patent publication No. 61 (1986) -272126, which has been discussed previously. In Figure 8b, only a few glass balls 70 and a few steel balls 72 are shown.



   Figure 8c schematically illustrates the porous electroformed body 68. The embossing surface 66 of the porous electroformed body 68, which has a pattern of surface irregularities, faces the porous layer 58 of the first molding die 40. The porous electroformed body 68 comprises cavities 68a, communication holes 68b and small holes 68c in the embossing surface 66.



   The porous electroformed body 68 is manufactured in the following manner. First, we create a precise model with a surface that has an embossing pattern similar to the surface pattern of a cowhide, for example, and then an electrically conductive layer is formed on the surface of the embossing pattern. .



  Very small particles of a synthetic resin, for example polypropylene, are attached by solvent welding to the electrically conductive layer, thanks to an organic solvent. Then, a metal is electrolytically deposited on the model with the embossing pattern by an electroforming process, thereby producing a porous electroformed body. The small particles of synthetic resin are then extracted from the porous electroformed body, which then has a high number of very small holes. For others

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 details, see Japanese Patent Publication No. 61 (1986) - 163290.



   As illustrated in FIG. 7, a frame sheep or ram 76 comprising cylindrical elements capable of sliding 74a to 74d, mounted to slide on the guide uprights 34a to 34d respectively is disposed between the die forging 42 and the lower plate 32. The chassis sheep 76 is coupled to a piston rod 70 extending downward from an auxiliary hydraulic cylinder 78 disposed on the lower surface of the upper plate 36. The chassis sheep 76 is equipped with gripping means 80.82 intended to grip one end of the unitary sheet S.



   The gripping means 80, 82 are of identical construction. Only the gripping means 80 will be described below with reference to Figures 9 and 10. The parts of the gripping means 82 which are identical to those of the gripping means 80 have been given the same reference numbers and will not be described in detail.



   The chassis member 76 is attached a fastening element 86 comprising a cylinder 90 fixed to its lower surface by a console 88. The cylinder 90 comprises a piston rod 90a coupled to a support 94 by means of a seal 92. Slides 96a, 96b are mounted on the support 94 and cooperate with guide rails 98a, 98b which are fixed to the attachment element 86.



   Sheet clamps 100a to 100c are mounted, as a sheet clamping mechanism, on the holder 94 at predetermined intervals. The sheet clamps 100a to 100c comprise first clamping arms 104a to 104c fixed to corresponding consoles 102a to 102c fixed to the support 94, and second clamping arms 108a to 108c angularly supported movably on the consoles 102a to 102c respectively , via corresponding axes 106. The second clamping arms 108a to 108c have proximal ends connected to the corresponding piston rods 112a to 112c of the cylinders 110a to 110c mounted on the brackets 102a to 102c respectively.

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   As illustrated in Figure 11, a pair of first parallel rails 114 is supported on the chassis sheep 76 and a loading cart 116 having a mechanism for holding a unit sheet S is mounted on the first rails 114. The loading cart 116 is illustrated in plan by Figure 12. In Figure 12, the loading carriage 116 is in the form of a frame carriage which comprises a pair of parallel elements 118, which are parallel to the first rails 114 and a transverse element 120 extending between the ends of the parallel elements 118, a pair of guide plates 122, intended to guide a unitary sheet S, being attached to the ends of the transverse element 120.

   Rollers 124 mounted for rolling in corresponding grooves formed in the first rails 114 are mounted on the opposite ends of the parallel elements 118. Supports 126 extend inwards from the distal ends of the parallel elements 118, and this one towards the other, hollow rectangular conduits 128 extending between the supports 126 and the transverse element 120. Axes 134 are rotatably supported on consoles 130, 132 and extend between them, these consoles being attached to the opposite ends of the rectangular conduits 128. As illustrated in FIG. 13, an arm 136 is secured to one end of each of the axes 134. A series of clamping levers 138 are mounted at spaced intervals on each of the axes 134.

   A needle 140 (Figure 13) intended to pierce and retain a unitary sheet S is embedded in each of the clamping levers 138. The loading carriage 116 of the previous construction is movable towards the device 100 for forming a cover sheet, thanks to a cylinder 142 (see Figure 11).



   Figures 14 and 15 illustrate an unloading means 150 for unloading a cover sheet 12 after it has been formed from a unit sheet S which has been fed by the loading carriage 116. Second rails 154 are supported by support pieces on a pair of cantilever beams 152 which are attached to the sliding members 74a, 74b. The second rails 154 are joined continuously to the first

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 rails 114 so that an unloading carriage 156 can move from the second rails 154 along the first rails 114 to the covering sheet forming device 30, where the unloading carriage 156 receives a formed covering sheet 12, after unloading it.

   Consequently, the first rails 114 are used by the loading carriage 116 and by the unloading carriage 156.



   The unloading carriage 156 is also in the form of a frame like the loading carriage 116. As illustrated in FIG. 15, the unloading carriage 156 comprises parallel elements 160 cooperating with the corresponding second rails 156 via a series of rollers 158, and a transverse element 164 extending between the ends of the elements 60 and joining these ends, the transverse element 164 supporting in cantilever frames 162 for the parts. Angularly movable arms 166a to 166d are connected to the frames 162.

   The arms 166a to 166d are angularly movable in the directions indicated by the arrows, thanks to the corresponding motors 168a to 168d (Figure 14), and they have corresponding support bars 170a to 170d on their distal ends to maintain the shape of a received covering sheet 12, the support bars 170a to 170d being able to be extended and contracted vertically.



   As illustrated in FIG. 16, the end ends of the second rails 154 are associated with a discharge device 172 for removing a cover sheet 12 from the discharge cart 156, and with a conveyor 174 intended to deliver only the cover sheet 12 which has been unloaded by the unloading device 172. This unloading device 172 comprises an unloading arm 176 intended to lift a covering sheet 12 from the unloading carriage 156, and a cylinder 178 to angularly move the following unloading arm 176 a predetermined angle.

   The unloading arm 176 is supported on beams 180,181 rotatably supported by a support shaft 182 which is coupled by a connecting lever 184 to a piston rod 178a of the cylinder 178. The conveyor 174 is

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 in the form of a belt conveyor in the illustrated embodiment.



   FIG. 11 also shows a loading device 190 intended to load a unitary sheet S, and a heating device 192 intended to heat a sheet S fed from the loading device 190 before the supply of this sheet S to the forming device cover sheet 30.



   The loading device 190 comprises a fixed chassis 194 with a pair of rails 196 arranged in a lower position in this chassis 194. A pallet 198 which supports a stack of unit sheets S is mounted on the rails 196 so as to be movable towards and away from the loading device 190. A vertically movable cylinder 200 is mounted on the top of the chassis 194 and it comprises a piston rod 202 at the lower end of which is attached a movable chassis 204.



   Support pieces 206 hang vertically from opposite ends of the movable frame 204, and a pair of rails 208 is supported by support pieces 206. The rails 208 extend parallel to each other in the direction in which a unitary sheet S is powered by the loading device 190. A cylinder 210 is fixed to one of the rails 208 to move the loading carriage 116.



   A cylinder 212 is fixed to the movable frame 204 and it comprises a piston rod at the lower distal end from which is attached a suction element 216 comprising a series of suction cups or suction discs 214 to preload a unitary sheet S to a given moment from the palette 198.



   The heating device 192 comprises a box-shaped housing 218 comprising an outlet duct 220 mounted on an upper part of this device. The housing 218 has upper openings 222 and lower openings 224 formed in the side walls. The upper openings 222 are selectively open and closed by doors 228 which are vertically movable by means of corresponding cylinders 226 mounted on the housing 218. A pair of upper parallel rails 230 on

  <Desc / Clms Page number 22>

 which the loading carriage 116 is movable, extends through the housing 218 and the upper openings 222. Likewise, a pair of parallel lower rails 232 extends through the housing 218 and the lower openings 224.

   A series of heaters 234 intended to soften a unitary sheet S by heat are arranged in the housing 218 above and below the upper rails 230.



   The rails 208 of the loading device 190 are movable vertically towards upper and lower limit positions, the upper limit position being designated by the two lines in a center line in FIG. 11. When the rails 208 are in the upper limit position, these rails are of a height equal to the upper rails 230 of the heating device 192. When the rails 208 are in the lower limit position, these rails are of a height equal to the lower rails 232 of the heating device 192. In the positions upper and lower limits, the rail ends 208 are arranged near the corresponding ends of the upper and lower rails 230,232 respectively.

   The first rails 114 of the covering sheet forming device 30 are also movable between upper and lower limit positions. When the first rails 114 are in the upper and lower positions, their ends are arranged near the corresponding ends of the upper and lower rails 230,232 respectively.



   Figure 17 illustrates a first forming device 250 for use in a first foaming step.



  The first forming device 250 comprises a base 258 on which is mounted a lower molding die 260 comprising a suction mechanism (not illustrated). Lateral mold dies 262a, 262b are pivotally supported on the base 258 by corresponding support pins 264a, 264b. Springs 266a, 266b act between the base 258 and the lower surfaces of the side molding dies 262a, 262b to normally push the side molding dies 262a, 262b toward each other. Cylinders 268a, 268b pivotally supported on base 258 have piston rods 270a, 270b coupled for operation with dies

  <Desc / Clms Page number 23>

 lateral molding 262a, 262b.



   An upper molding die 272 is arranged to move vertically above the lower molding die 260 and the side molding dies 262a, 262b. The upper, lower and lateral molding dies 272,260, 262a, 262b jointly define a cavity 274 which communicates with a nozzle 278 by a passage 276. A magnet 280 intended to attract and retain by magnetic means the first component 16 is attached to the upper molding die 272 in a predetermined position, and a series of clamp means 282 for holding together the molding dies of the first forming device 250 are mounted on the upper molding die 272. Each of the clamp means 282 comprises a cylinder 284 having a piston rod 286 which is coupled to one end of a rocker arm 288.

   An essentially central part of the rocker arm 288 is supported on the upper molding die 272 by a spindle 290, a roller 292 being rotatably supported on the lower end of the rocker arm 288. When the cylinders 284 are actuated, the rollers 292 are pressed against the internal wall surfaces of the cylindrical contact elements 294 mounted on the corresponding lateral molding dies 262a, 262b to clamp the molding dies of the first forming device 250.



   A covering sheet positioning device 330, intended to place a covering sheet 12 in the first forming device 250 is illustrated in FIGS. 18 and 19.



   The device 330 for placing the cover sheet comprises a frame 332 comprising a pair of long parallel pipes 334 and five shorter reinforcement pipes 336 extending transversely between the pipes 334. These pipes 334,336 are in the form of pipes glass fibers, epoxidized or carbon fibers, or epoxidized resins. The shorter pipes 336 will also be gripped by the operator when the latter manipulates the device 330 for placing a covering sheet.

  <Desc / Clms Page number 24>

 



   To the pipes 334,336 are connected the ends of a series of resin support pipes 338, similar to the pipes 334,336. A resin profiled member 340, which is shaped as a skeleton of a cover sheet 12 is supported on the other ends of the support conduits 338. The profiled member 340 is made of glass fibers and epoxidized resin so to have a predetermined degree of rigidity and it comprises a series of pressure elements 342 of a shape complementary to certain parts of a covering sheet 12. The pressure elements 342 are made of a urethane elastomer for example , so that they do not damage a cover sheet 12 while they are pressed against it.

   As illustrated in FIG. 19, the pressure elements 342 are located in alignment with complex and acute angular zones, such as the attachment zone A (FIG. La) of the lining element 10, and they comprise elements of pressure 342a, 342b, 342c, the pressure element 342a corresponding to the attachment zone A.



   A second forming device (see Figure 20) intended to be used in a second foaming phase is essentially of a structure identical to the first forming device 250 described above and will not be described in detail. The elements of the second forming device 350 which are identical to those of the first forming device 250 have been given the same reference numbers. The second forming device 350 comprises a cavity 396 and the configuration of an upper molding die 272a of the second forming device 350 is chosen to place the second component 20 in the cavity 396.



   Although not shown, a blowing device intended for removing a separating agent which is attached to an intermediate body is disposed between the first and the second forming device 250, 350, as will be described below, and a deburring device is arranged downstream of the second forming device 350.



   The apparatus for implementing a method of manufacturing the trim element for a motor vehicle

  <Desc / Clms Page number 25>

 according to the present invention is basically constructed in the manner described above. The operation and advantages of the device will be described below.



   In FIG. 11, the sheet pallet 198 is first introduced into the lower position of the loading device 190, then the cylinder 212 is actuated to lower the suction element 216. The upper sheet among the sheets S stacked on the sheet pallet 298 is drawn upwards by the suction cups 214 of the suction device 216. Then, the attracted unitary sheet S is raised to the rails 208 by the cylinder 212. During this period, the loading carriage 216 is stopped at rest on the lower rails 282 of the heating device 192.



   Then, the cylinder 210 is actuated to bring a contact element 210b (Figure 11) provided on the distal end of a piston rod 210a, in contact with the loading carriage 116. The piston rod 210a is retracted to bring the loading trolley 116 to run along the lower rails 232, and then on the rails 208 to a position situated below the unitary sheet S. which is attracted by the suction cups 214.



   A cylinder (not shown) mounted on the lower surface of the movable chassis 204 is actuated to tilt the arms 136 of the loading carriage 116 in the direction indicated by the arrow A (Figure 13) until the clamping levers 138 fall on the rectangular pipes 128. The needles 140 embedded in the distal ends of the clamping levers 128 then pierce the unitary sheet S and then penetrate into holes (not illustrated) provided in the rectangular conduits 128, after which the unitary sheet S is held in place on these rectangular conduits 128. When the sheet S is completely held in place on the rectangular conduits 128, the suction cups 214 are deactivated to release this sheet S.



   Then, the cylinder 200 is actuated to lift the movable frame 204 and the rails 208 on which the loading carriage 116 is at rest to a position situated at the same height as the upper rails 230 of the heating device 192.

  <Desc / Clms Page number 26>

 The cylinder 210 is then actuated to allow the piston rod 210a to move the loading carriage 116 which carries the unitary sheet S along the rails 208 and then along the upper rails 230 towards the heater 192, while at the same time the unitary sheet S is heated to a temperature close to its softening point by the heating devices 234.



   At the same time, the frame lug 76 of the cover sheet former 30 was lifted so that the first rails 114 supported by the frame liner 76 are at the same height as the top rails 230.



   The cylinder 142 supported on the chassis sheep 76 is then put into operation to extend its piston rod 142a in the heating device 192 until the distal end of the piston rod 142a is coupled to the loading carriage 116 Next, the cylinder 142 is inverted with respect to its operation to retract the piston rod 142a. The loading carriage 116 which supports the unitary sheet S circulates along the upper rails 230 and then along the first rails 114 until this loading carriage 116 reaches a position below the second molding die 46 of the covering sheet forming device 30 (see Figure 21a and phase 1 in Figure 22).



   Then, the piston rod 78a of the auxiliary hydraulic cylinder 78 is lowered to lower the chassis sheep 76 at the same time as the loading carriage 116 which supports the unit sheet S. At the same time, the piston rod 43a of the hydraulic cylinder 43 is lowered to move the second molding die 46 down in unison with the stamping sheep 42 (see Figure 21b and phase 2 of Figure 22).



   When the first and second molding die 40,46 correspond, the clearance K which is slightly smaller than the thickness of the unitary sheet S is left between them. The unitary sheet S is then held against the corresponding surfaces, that is to say the convex and concave forming surfaces, of the first and of the second molding die 40, 42 under a predefined air pressure.

  <Desc / Clms Page number 27>

 finished. As the unitary sheet S has already been heated, it is soft and flexible to the point that it is shaped along the corresponding surfaces of the first and second molding die 40, 42.



   Then, pressurized air is supplied from the air source into the first molding die 40 by the air tank 48 arranged in the lower plate 32 of the covering sheet forming device 30. The supplied air circulates through the conduit 48a and also passes through the ventilation holes formed between the glass beads 70 of the porous layer 54. and then through the ventilation holes formed between the steel balls 72 of the layer porous 58. The air leaves following the porous layer 58 to go into the space K in order to press the unitary sheet S gripped between the first and the second molding die 40, 46 against the embossing surface 66 of the porous electroformed body 68 (see Figure. 21c and phase 3 of Figure 22).



   As the porous layer 58 has a very large number of communication or ventilation holes, the unitary sheet S is pressed under the uniform air pressure applied to its entire surface against the embossing surface 66 of the porous electroformed body 68 of the second molding die 46. The foam construction of the unitary sheet S cannot thus locally deform or be crushed, so that the desired embossed design can be well transferred from the embossing surface 66 to the unitary sheet S, even if the embossing design is complex.



   After a predetermined period of time, the vacuum pump is actuated to evacuate the vacuum tank 50 from the upper plate 36. As a result, the unitary sheet S is attracted to the vacuum tank 50 through the holes 68c, 68b of the body porous electroformed 68, the ventilation holes of the porous layers 64, 60 and the suction duct 50a (see Figure 21d and phase 4 of Figure 22). As the second molding die 46 has a very large number of very small communication or ventilation holes, the unitary sheet S is attracted towards the embossing surface 66 under an essentially uniform pressure.

   The unitary sheet

  <Desc / Clms Page number 28>

 S is pressed against the hollowed out surface portions 52a, 52b, with the consequence that the embossed design will be transferred securely from the embossing surface 66 to the unit sheet S. After the embossing design has been completely transferred to the unit sheet S, which is thus shaped as a covering sheet 12, the supply of pressurized air to the first molding die 40 is stopped according to phase 5 of FIG. 22, then the evacuation of the second molding die 46 is stopped during phase 5, and the second molding die 46 is vented during phase 7.



   When the second molding die 46 is vented, the embossed unitary sheet S can be easily released from the first and second molding die 40,46.



   The loading carriage 116 is controlled by the cylinder 142 to circulate from the first rails 114 on the bottom rails 232 in the heater 192, where the loading carriage 116 is prepared to carry a following unitary sheet S.



   In the case of Figures 9 and 10, the cylinders 110a to 110c of the sheet clamps 100a to 100c of the gripping devices 80,82 are actuated to rotate the second clamping arms 108a to 108c in the direction indicated by the arrows until 'that one end of the covering sheet 12 is gripped by the ends of the first clamping arms 104a to 104c and by the second clamping arms 108a to 108c.



   The first and second molding die 40,46 are moved away from each other, and the cover sheet 12 is removed from its position between this first and this second molding die 40,46 (phase 8).



   As illustrated in Figure 6, the cover sheet 12 can be removed by moving the stamping sheep 42 and the chassis sheep 76 at different speeds, for example by lifting the chassis sheep 76 at a speed which is half the one to which the muttering sheep 42 is raised. More specifically, the chassis sheep 76 is raised at a higher speed.

  <Desc / Clms Page number 29>

 lower than that of the sheep to be stamped 42 by adjusting the speed of circulation of oil supplied under pressure to the hydraulic cylinder 43 and the speed of circulation of oil supplied under pressure to the cylinder 78.

   As the distance between the second molding die 46 maintained by the stamping sheep 42 and the gripping means 80,82 maintained by the chassis sheep 76 and gripping the cover sheet 12 is gradually increased at this stage, this sheet of cover 12 can automatically and safely be removed from second molding die 46. The second molding die 46 and the chassis pin 76 are finally stopped in the positions illustrated in Figure 6.



   Next, the cover sheet 12 is placed on the unloading carriage 156 and unloaded from the apparatus. As illustrated in FIG. 7, the unloading carriage 156 is moved along the second rails 154 and then along the first rails 114 of the chassis sheep 76 to a position situated below the second molding die 46.

   The arms 166a to 166d which have been directed parallel to the elements 160 to avoid interference with the sheet clamps 100a to 100c are oriented in a direction indicated by the arrows thanks to the motors 168a to 168c to bring the support bars 170a to 170d located on the distal ends of the arms 166a to 166d to a position suitable for receiving the cover sheet 12 (see Figure 15). The cylinders 110a to 110c are then actuated to move the second clamping arms 108a to 108d away from the first clamping arms 104a to 104d, thus allowing the cover sheet 12 to fall onto the unloading carriage 156.



     At this time, the cover sheet 12 is supported by the support bars 170a to 170d which serve as means for maintaining the configuration of this cover sheet 12. As this cover sheet 12 is at high temperature and of poor rigidity immediately after it was removed from the molding dies 40,46, if the cover sheet 12 fell directly onto the unloading carriage 156, this cover sheet 12 would be deformed and would remain

  <Desc / Clms Page number 30>

 distorted when the temperature drops, resulting in a defective product.

   The templates or support bars 170a to 170d provided on the unloading carriage 156 in the illustrated embodiment serve as means for maintaining the configuration of the cover sheet 12, so that the preceding drawback is eliminated. The means for maintaining the configuration of the covering sheet 12 may be air jets leaving the distal ends of the arms 166a to 166d. The air thus supplied from the arms 166a to 166d is also effective in cooling the covering sheet 12.



   Then, the unloading carriage 156 is moved along the first rails 114 and the second rails 156 towards their ends, after which the unloading device 172 is put into operation to discharge the covering sheet 12 on the conveyor 174.



   More particularly, as illustrated in FIG. 16, the piston rod 178a of the piston 178 is extended to rotate the unloading arm 176 around the support axis 182 towards the conveyor 172. The cover sheet 12 which has been supported by the support arms 170a to 170d is then lifted by the unloading arm 176. When the unloading arm 176 is tilted at a significant angle, the cover sheet 12 slides along the unloading arm 176 towards and on the conveyor 174. Next, the covering sheet 12 is fed by the conveyor 174 to a following process, that is to say to the first forming device 250 for the first foaming process.



   In the second forming device 250, the upper molding die 272 has been raised, it has been coated with a separating agent, and the supports 22 of the first component 16 are attached to the magnet 280. The cover sheet 12 which has been fed from the cover sheet former 30 is inverted 1800 or turned upward so that its embossed surface faces downward, and the cover sheet 12 is held in close contact with the die

  <Desc / Clms Page number 31>

 lower molding 260 and the lateral molding dies 262a, 262b by the device 330 for positioning the cover sheet.

   More specifically, one of the conduits 336 of the chassis 332 of the device 330 for placing the cover sheet is gripped by the operator and the pressure devices 342 of the profiled element 340 are placed in alignment with parts of the cover sheet 12. At this time, as illustrated in FIG. 19, the pressure element 342a which has a strongly angular face is oriented towards the attachment zone A of the cover sheet 12. Consequently, the pressure device 342a is held against the opposite side of the cover sheet 12 at the attachment zone A, and the pressure devices 342b, 342c are held against their corresponding areas of the cover sheet 12. Under these conditions, the frame 332 is pressed against the lower molding die 260.

   The pressure devices 342 are securely pressed against the desired areas of the cover sheet 12, and thus, for example, the pressure device 342a is pressed against the attachment area A, so that the cover sheet 12 is held precisely, intimately against the lower molding die 260 and the side molding dies 262a, 262b.



   As illustrated in Figure 2a, the cover sheet 12 is of a very complex shape. If the cover sheet 12 were to be held manually against the bottom molding die 260 and the side molding dies 262a, 262b directly by the operator's fingers, it would be very tedious and time consuming to hold the cover sheet 12 in place. . The operator's fingers could not be introduced against a strongly angular zone, such as the attachment zone A, thus leaving an undesirable gap between the covering sheet 12 and the lower molding die 260.



   On the other hand, the device 330 for positioning the cover sheet comprises a series of pressure elements or devices 342 of a shape complementary to that of the cover sheet 12, these pressure devices being capable of

  <Desc / Clms Page number 32>

 intimately and securely hold the areas of the cover sheet 12 against the lower molding die 260 and the side molding dies 262a, 262b, simply by pressing the frame 332 against the lower molding die 260 at the request of the operator.

   Consequently, the device 330 for placing the cover sheet does not present the problem of the different pressure conditions of the cover sheet 12, which would otherwise be created by the operator who would use his fingers to press the cover sheet 12, and neither does it suffer from the problem of wrinkling or other defects which would otherwise result from the gaps between the cover sheet 12 and the lower molding die 260 and the side molding dies 262a, 262b. The cover sheet 12 can thus be fixed in place very precisely in a short period of time with the result that a high quality filling element can be efficiently produced by the first and second forming device 250 , 350.



   Since the pressure devices 342 which will come into direct contact with the cover sheet 12 are made of a soft material, for example a urethane elastomer, the cover sheet 12 is not damaged or broken by the pressure devices 142 when this sheet is pressed by the device 330 for placing the cover sheet.



   The frame 332, the support conduits 338 and the profiled element 340 of the device 330 for placing the covering sheet are made of a resin material. Consequently, the device 330 for placing the covering sheet is of light weight as a whole and can be easily handled.



   While the cover sheet 12 is pressed against the lower molding die 260 and the side molding dies 262a, 262b by the device 330 for placing the cover sheet, a suction mechanism (not shown) arranged in the lower molding die 260 is actuated to attract the cover sheet 12 against this lower molding die

  <Desc / Clms Page number 33>

 260. After the device for placing the cover sheet 330 has been moved upward, the cover sheet 12 then remains in intimate contact with the lower molding die 260 and the side molding dies 262a, 262b. .



   As illustrated in Figure 17, after the upper molding die 272 has been lowered, the cylinders 284 of the clamps 282 are actuated to move the piston rods 286 outward. The pivoting arms 288 connected to the piston rods 286 are angularly displaced around the support pins 290 to bring the rollers 292 against the internal wall surfaces of the contact elements 292 on the lateral molding dies 262a, 262b, thereby tightening the assembly of the molding dies of the first forming device 250. At this moment, the first component 16 (FIG. 2a) is placed at a predetermined location on the covering sheet 12.



   Then, a solution of foam resin, such as a solution of hard urethane foam, is applied from the nozzle 278 through the passage 276 to the first forming device 250 in the cavity 274 until that -filled. The supplied solution is then transformed into foam by heating the cavity 274, which thus forms a first foam body 14 on the rear side of the cover sheet 12. As the first component 16 is held on the upper molding die 272 by a magnet 280, part of the first component 16 is embedded in the first foam body 14, as illustrated in Figure 2b. At this stage, a rib 14a and an attachment base 14b for the positioning of the second component 20 are formed on the first foam body 14.



   After forming in one piece an intermediate body 10a, which is composed of the covering sheet 12, the first foam body 14 and the first component 16, the assembly of the molding dies of the first forming device 250 is opened. More particularly, the cylinders 284 of the clamping means 282 are actuated to move the piston rods 286 inwardly in order to eliminate the contact of the rollers 292 with the elements of

  <Desc / Clms Page number 34>

 contact 294. The upper molding dies 272 are raised and the cylinders 268a, 268b provided on the base 258 are put into operation to move their piston rods 270a, 270b in a direction making it possible to angularly move the lateral molding dies 262a, 262b away from each other against the elastic forces of the springs 266a, 266b.

   The suction mechanism of the lower molding die 260 is deactivated, and the intermediate body 10a is withdrawn from the first forming device 250 by a supply device (not shown).



   As the upper molding die 272 is coated with the release agent to allow the intermediate body 10a to be easily separated from the assembly of the molding dies, as described above, the release agent tends to to remain attached to the intermediate body 10a. Therefore, the intermediate body 10a which has been removed from the first forming device 250 is sent to the blowing device (not shown), in which the separating agent is blown out from the first foam body 14 of the intermediate body 10a .



   Then, the intermediate body 10a is sent from the blowing device to the second forming device 350 for the second foaming process. In the second forming device 350, the upper molding die 272a was lifted.



  The intermediate body 10a is first placed on the lower molding die 260 and on the lateral molding dies 262a, 262b. The second component 20 comprising the rear instrument box 24, the clock case 26 and the lateral conduit 28, all made of a resinous material, is placed on the first foam body 14.



  More particularly, as illustrated in FIG. 2c, the rear instrument box 24 is placed on the rib 14. a and on the attachment base 14b. Then, the upper molding die 272a is lowered to close all of the molding dies of the second forming device 350.



   Then, a solution of hard urethane foam resin is poured through the nozzle 278 into the cavity 396, which is then heated to form a second foam body 18 formed of a

  <Desc / Clms Page number 35>

 part with the intermediate body 10a, after which the second component 20, such as a rear instrument box 24, is partially embedded in the second foam body 18. As illustrated in FIG. 20, the solution of the foam resin d the hard urethane cannot leak into undesirable areas thanks to the seal elements N attached to the rear instrument box 24. The second component 20 is precisely positioned by the rib 14a and the attachment base 14b.



   Then, all of the molding dies of the second forming device 350 are opened, and a molded body 10b, which is composed of the covering sheet 12, the first foam body 14, the first component 16, the second body in foam 18 and the second component 20, is removed from all of the molding dies. The ends of the molded body 10b and its opening are deburred by a deburring device (not shown), after which a packing element 10 is finished as a product.



   In the case of the previous embodiment, the covering sheet 12 having a predetermined three-dimensional configuration and an embossed drawing surface is placed in the first forming device 250 and, while the first component 16 in the form of a magnetic metallic material is held on the upper molding die 272 by the magnet 280, the intermediate body 10a composed of the covering sheet 12, the first foam body 14, and the first component 16 is formed in the first foaming process .

   After the remaining separating agent has been blown out from the intermediate body 10a, this is sent to the second forming device 350, the second component 20 of a resin material is placed on the intermediate body 10a, and the molded body Ob is formed in the second foaming process. The molded body 10b is then trimmed to form the packing element 10 intended for a motor vehicle.



   The first and second component 16,20, such as the supports 22 and the various boxes 24,26, which have hitherto been mounted by means of screws or similar means are molded in

  <Desc / Clms Page number 36>

 the first and second foam bodies 14, 18, when the latter are molded. Therefore, these components can easily be attached without the need for manual labor and a complex process which would otherwise be required if screws or other fastening means were to be used. As a result, the method of manufacturing the packing member 10 is greatly simplified and made efficient, so that the whole of this method can easily be automated.



   The rigidity of the packing element 10 as a whole can be maintained by the first and second foam bodies 14,18 in resin, hard urethane foam, without the use of any cores and any screws. The packing element 10 is thus light in its entirety.



   The trim element 10 is also advantageous in that it does not make any noise when the motor vehicle is in operation because it is of a unitary construction instead of being composed of joined sections. The trim element 10 is thus effective in making the passenger compartment quieter during the movement of the motor vehicle. Since no seal or rim is visible on the surface of the packing element 10, it has a rich, sophisticated and solid appearance.



   The synthetic resin sheet used as a covering sheet has been described as a laminated synthetic resin sheet, comprising a body of polypropylene foam or the like. However, the present invention is also applicable to a single synthetic resin sheet. The porous layers comprising numerous very small holes or interstices and serving as reinforcements, and the porous layers comprising the temperature control pipes may be replaced by porous resinous layers. The air tank and the vacuum tanks of the forming device can be switched into position.



   A device 400 for placing a cover sheet according to another embodiment is illustrated in FIGS. 23 to 26. The device 400 for placing a cover sheet comprises a frame 402 comprising four

  <Desc / Clms Page number 37>

 pipes 404 which extend essentially parallel to each other as illustrated in Figure 24. The frame 402 is made of a resin material. Any of the pipes 404 can be gripped by the operator during the operation of the device 400 for placing the cover sheet. A profiled element 406 which is essentially complementary as regards its shape with the covering sheet 12 is directly supported on the frame 402.



   The profiled element 406 comprises a first projecting part, essentially curved 408a complementary as regards its shape from the attachment zone A, and a second projecting part, box-shaped, 408b corresponding to the storage box C The profiled element 406 also includes a cavity 410 corresponding in position to the glove box D.



   A series of pressure elements 412 for pressing the rear side of the cover sheet 12 are attached to the profile element 406 in predetermined areas thereof. The pressure elements 412 are made of a relatively soft material, such as a urethane elastomer. A set 414 is created between two adjacent pressure elements 412. The profiled element 406 also has an opening 415 and a series of holes (not shown).



   Each of the pressure elements 412 is associated with a suction device 416. More particularly, as illustrated in FIG. 26, each of the pressure elements 412 has a small diameter suction hole 418 often outwards and communicating with an opening 420 existing between the pressing element 412 and the profiled element 406. The opening 420 is filled with beads of styrene or epoxy resin, thereby forming a layer of porous resin 422. A conduit 424 has a end connected to the profiled element 406 in communication with the opening 420.



  The other end of the conduit 424 is connected to a conduit 426 of a resin material (Figure 24) which is disposed in the profiled element 406 and fixed to the frame 402 in close relation thereto. The conduit 426 communicates with a vacuum pump 428.



   The conduits 424 of the suction device 416 of the pressure elements 412 are connected to a common conduit 426. This

  <Desc / Clms Page number 38>

 could be omitted and the frame 402 itself could be used as a suction line.



   The device 400 for placing the covering sheet is basically constructed in the manner described above. The operation and the advantages of the device 400 for installing the covering sheet will be described below.



   After a cover sheet 12 has been brought to a predetermined shape, its reverse side is kept in contact with the device 400 for placing the cover sheet. At this time, the pressing elements 412 abut the inclined or narrow parts or zones of the covering sheet 12. Next, the suction device 416 of the corresponding pressing elements 412 is put into operation.



   More particularly, the vacuum pump 408 connected to the common conduit 86 connected to the conduits 424 of the suction device 416 is put into operation to put the conduits 424 under vacuum. Therefore, air in the suction holes 418 is drawn through the openings 420 to attract the parts of the cover sheet 12, which are in contact with the pressing members 412 thereto through the intermediate the suction device 416. Since the porous resin layer 422 is arranged in the opening 420, a vacuum which would be excessively high cannot act in the suction hole 418 and, therefore, the sheet of cover 12 is not unduly distorted.



   When the cover sheet 12 is attracted to the pressure elements 412, the air between this cover sheet 12 and the profiled element 406 is discharged through the opening 415 and the other holes (not shown) created in the profiled element 406. The covering sheet 12 is thus attracted and securely held by the pressure elements 412.



   Then, the operator grasps one of the conduits 404 of the frame 402 and moves the cover sheet 12 attracted towards the device 400 for placing this cover sheet, in the direction of the first forming device 250. After the surface of the cover sheet 12 which is attracted and held by

  <Desc / Clms Page number 39>

 the device 400 for positioning this covering sheet has been pressed intimately against the corresponding surfaces of the lower molding die 260 and of the lateral molding dies 262a, 262b of the first forming device 250, the vacuum pump 428 connected to the conduit 426 is inactivated.

   The suction mechanism (not shown) of the lower molding die 260 is then put into operation to attract the covering sheet 12 towards the lower molding die 260. Next, the device 400 for placing the covering sheet is moved away from the lower molding die 260 and the side molding dies 262a, 262b. As the covering sheet 12 is no longer attracted to the device 400 for placing this covering sheet, the latter is released from the device 400, while it is kept in intimate contact with the lower molding die 260 and the lateral molding dies 262a, 262b.



   The covering sheet positioning device 400 can easily and quickly process the covering sheet 12 of a complex shape in the first forming device 250. Before the covering sheet 12 is placed in the first forming device 250, this cover sheet is attracted towards the device 400 for placing this cover sheet by the suction device 416. Consequently, the configuration of the surface of the cover sheet 12 can be confirmed by the operator. before being set in the first forming device 12, so that one can produce a packing element 10 of better quality.



   Each of the pressure elements 342 of the device 330 for positioning the covering sheet of the previous embodiment can be equipped with the same suction means as the suction means 416, and the frame 332 and the support conduits 338 of the device 330 for placing the covering sheet can be used as suction conduits.



   Figure 27 shows a packing element 500 for a motor vehicle, according to another embodiment of the present invention.

  <Desc / Clms Page number 40>

 



   The packing member 500 includes a cover sheet 510 made of vinyl chloride or the like, a first foam body 512 formed of a foam resin, a component 514, such as, for example, a conduit for cooling or heating air passage, or a box for mounting an air conditioning unit, and a second foam body 516 made of a foam resin. The cover sheet 510 has an outer surface having an embossed design which gives the impression of leather or the like. The first foam body 512 has positioning ribs 512a, 512b for positioning the component 514. The cover sheet 510 has a predetermined three-dimensional configuration.

   The first foam body 512 is caused to foam on the cover sheet 510 by means of a foaming device (described below). The component 514 is placed on the first foam body 512 so as to be positioned by the ribs 512a, 512b.



   Component 514 has a projection 514a arranged in spaced relation to the first foam body 512.



  Preferably, a urethane foam is caused to flow near the component 514 and around the projection 514a, thereby forming the second foam body 516.



   The foam bodies 512, 516 are of a double wall construction, the second foam body 516 surrounding the projection 514a. The body of component 514 is sandwiched between the first and second foam bodies 512, 516, and the projection 514a is held by the second foam body 516 only.



   The first and second foam bodies 512, 516
 EMI40.1
 are formed by the first and second forming device 520, 522, which are illustrated in FIGS. 28 and 29. The parts of forming devices 520, 522 which are identical to those of the first and second forming device 250 , 350 illustrated in Figures 17 and 20 have been given the same reference numbers, and will not be described in detail.



   As illustrated in FIG. 28, a cavity 524 intended to form the first foam body 512 comprising the

  <Desc / Clms Page number 41>

 positioning ribs 512a, 512b is defined between the lower mold die 260 and the upper mold die 272, when the first forming device 520 in which the covering sheet 510 is placed is blocked by the clamping means 282. The cavity 524 includes cavities 524a, 524b defined in the upper mold matrix 272 to form the positioning ribs 512a, 512b.



   As illustrated in FIG. 29, the upper molding die 272a of the second forming device 522 has a cavity 526 intended to form the second foam body 512, and the nozzle 278 opens in the cavity 526.



   In operation, the cover sheet 510 which has been formed in advance is placed on the lower mold die 260 of the first forming device 520, then the upper and lower molding dies 272,260 are assembled. At this stage, as described above, the cavity 524 intended to form the first foam body 512 having the positioning ribs 512a, 512b is defined between the lower and upper molding dies 260,272.



   Then, a solution of foam resin is poured into the cavity 524 to thereby form the first foam body 512. After opening all of the molding dies of the first forming device 520, the covering sheet is removed on which is formed the first 512 foam body.



   The cover sheet 510 is then placed on the lower molding die 260 of the second forming device 522, and the fastener 514 is arranged in alignment with the positioning ribs 512a, 512b of the first foam body 512, as shown by Figure 29. The set of molding dies of the second forming device 522 is closed and a solution of foam resin is poured into the cavity 526 to thereby form the second foam body 516 near the positioning ribs 512a, 512b , by embedding the projection 514a of the component 514. The packing element 500 which is then finished as product is removed from the second forming device 522 and sent to a following assembly line.

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   The component 514 of the packing element 500 thus produced is held in place by the positioning ribs 512a, 512b, and is partially covered by the second foam body 516. Consequently, the component 512 cannot be moved into position. and the packing element 500 is therefore of high quality.



   Figures 30a and 30b illustrate a trim element for a motor vehicle according to yet another embodiment of the present invention. A packing member 570 includes a cover sheet 571 made of vinyl chloride or the like, a first foam body 572, a component 574, joint members 576 made of elastic material, and second foam bodies 578 The first foam body 572 comprises a step 572a and a rib 572b for the positioning of the component 574. This component 574 comprises an end portion 574a and a flat surface 574b intended to be applied respectively to the step 572a and to the rib 572b of the first foam body 572.

   One of the elastic joint elements 576 is interposed between the end part 574a of the component 574 and the step 572a of the first foam body 572, and one of the second foam bodies 578 is formed on the step 572a. The other elastic seal element 576 is interposed between the rib 572b of the first foam body 572 and the flat area 574b of the component 574, and the other second foam body 578 is formed near the rib 572b to cover the end. distal of the flat area 574b.



   The packing element 570 of the previous structure is manufactured in the same manner as that which has been described previously. More particularly, when the seal elements 576 are placed on the step 572a and the rib 572b which were formed in the first foaming process, the end portion 574a and the flat area 574b of the component 574 are placed on the seal elements 576 These elements are clamped between molding dies (not shown).

   Then a solution of a foam resin is poured to form the second foam bodies 578 (Figure 30b) near the end portion 574a, the flat area 574b and the rib

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   572b. As the elastic joint element 574 is interposed between the end part 574a and the step 572a, the foam resin solution cannot leak between the end part 574a and the step 572a when the solution is poured.



   As the seal element 576 is also interposed between the flat area 574b and the positioning rib 572b, the foam resin solution which will surround the contacting parts of the rib 572b and of the component 574 cannot escape. Consequently, after the second foam body 578 has been formed during the second foaming process, there is no need to complete the second foam body 578 as it does not have unwanted burrs. The component 574 is supported by the elastic joint elements 576, and stresses applied by external forces are absorbed by the joint elements 576.



  Therefore, after the finished trim element 570 has been installed in a motor vehicle, this trim element 570 will not make noise even if the motor vehicle vibrates while it is traveling.



   A method of manufacturing a trim element for a motor vehicle according to another embodiment of the present invention will be described below. Figure 31 schematically illustrates a packing element 600 for a motor vehicle, this packing being produced by this method.



   The packing element 600 comprises a covering sheet 612 of vinyl chloride or the like, serving as an artificial leather sheet, and a shaped body 614 made of a foam resin, for example a hard urethane resin.



  The packing element 600 has spaces or cavities, one of which is indicated in the form of a box 620 for receiving an air conditioning unit or an audio device. The trim element 600 has a cavity 622 defined in one of its upper surfaces for housing a clock (not shown) when the trim element 600 is installed on the front part of a motor vehicle, and it also includes a track 624 projecting outward for aesthetic reasons. The manufacturing process for this form

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 of realization aims at the precise formation of the cavity 622 and the range 624.



   FIG. 32 illustrates in cross section a forming device 632 for the manufacture of the lining element 60.



   The forming device 632 comprises a lower female molding die 634, lateral molding dies 635a, 635b, and an upper male molding die 636. These molding dies have corresponding surfaces forming the product, these surfaces jointly defining a cavity. 638 of a shape complementary to the packing element 600.



   The lower molding die 634 is fixedly mounted on a die base 646 and it has hollow spaces or cavities 648, 650. The cavities 648,650 communicate with each other by a communication or ventilation hole 652. A conduit 654 connected to a vacuum pump 656 communicates with the cavity 650. The lateral molding die 635a comprises cavities 662, 663 communicating with each other through a communication or ventilation hole 664. The cavity 663 communicates with the cavity 648 of the lower molding die 634 through a ventilation hole 665.



  A padding 666 is interposed between the corresponding surfaces of the lateral molding die 635a and of the lower molding die 634 in order to make the cavities of the lateral molding die 635a and of the lower molding die 634 airtight. similarly, the lateral molding die 635b comprises cavities 668,670, 672, the cavities 668,670 communicating with each other by a ventilation hole 674. The cavity 670 communicates with the cavity 650 of the lower molding die 634 by a ventilation hole 676. A jam is interposed between the corresponding surfaces of the lower molding die 634 and the lateral molding die 635b.



   The corresponding surfaces or product forming surfaces of the lower molding die 634 and the side molding dies 635a, 635b, which define the cavity 638, should preferably be made of a porous electroformed body having

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 a very large number of very small holes serving as suction holes to attract the cover sheet 612 under the effect of the vacuum. However, instead of such a porous electroformed body, the corresponding surfaces which define the cavity 638 may include suction holes communicating with this cavity 638.



   In the lateral molding die 635b, is disposed a sliding core 686 intended to bring a certain shape to the molded product, a cylinder 688 being provided to move this sliding core 686 back and forth.



   The upper molding die 636 is movable vertically and has a hole 702 defined in one of its ends. A casting duct 704 in which a resin injection head 703 is fitted is mounted in the hole 702. The upper molding die 636 has cavities 706,708 which are defined therein so that this upper molding die 636 is of reduced weight.



   The other elements of the forming device 632 are identical to those of the first forming device 650 illustrated in FIG. 17, and they have been given the same reference numbers and will not be described in detail.



   The forming device 632 is basically constructed as described above. The manufacturing method of the present embodiment is carried out on the forming device 632 to form the packing element 600. The manufacturing method will be described below with particular emphasis on the formation of the cavity 622 in the upper surface of the packing element 600.



   The covering sheet 612 which has been shaped into a product by another set of molding dies is pressed against the lower molding die 612 and the lateral molding dies 635a, 635b by the device for placing the covering sheet .



   Then, the cavities defined in the lower molding die 634 and in the lateral molding dies 635a, 635b are evacuated by the vacuum pump 656. The cavity

  <Desc / Clms Page number 46>

 650 existing in the lower molding die 634 communicates with the cavity 648 through the ventilation hole 652, the cavities 662, 663 of the lateral molding die 635a communicate with the cavity 648 of the lower molding die 634 through the ventilation holes 664, 665, and the cavities 668,672 of the lateral molding die 635b communicate with the cavity 650 of the lower molding die 634 through the ventilation holes 674,676. Therefore, all of these cavities are evacuated.

   The cover sheet 612 is then pressed against the corresponding surfaces of the lower molding die 634 and the side molding dies 635a, 635b under a vacuum developed through the suction holes defined in the product forming surface of the lower die 634 (see Figure 34a). Then, the upper molding die 636 is lowered until the set of molding dies, consisting of the upper molding die 636, the lower molding die 634 and the side molding dies 635a, 635b are closed. .



   As illustrated in Figure 33b, the sliding core 686 is moved into the cavity 638 by the cylinder 688 to offset part of the cover sheet 612 relative to the surface forming the product.



   Then, the cavity 638 is filled with a resin material. In this case, a solution of polyol and diisocyanate is poured through the injection head 703 to form a body of hard polyurethane foam. After the tip of the injection head 702 has been applied in the pouring duct 704, the polyol and diisocyanate solution is injected under a certain pressure from the injection head 703. The solution is loaded into the cavity 638 while its resin materials are mixed together. The solution is transformed into foam by the mixture of these two resin materials. As illustrated in Figure 33c, the cover sheet 612 is brought into close contact with the sliding core 686 under the pressure of carbon dioxide which is produced during the foaming reaction.

   The foam resin materials can then be allowed to harden while the above conditions are main-

  <Desc / Clms Page number 47>

 held over a predetermined period of time. As a result, the cavity 622 is precisely shaped by the shape of the tip of the sliding core 686.



   After hardening of the resin materials, the sliding core 686 is withdrawn downwards considering FIG. 33d, and the assembly of the molding dies is opened, the finished packing element 600 being removed.



   In the previous description, the sliding core 686 is moved into the cavity 638 to form the cavity 622 in the product. On the other hand, the pad 624 illustrated in FIG. 31 can be formed on the upper surface of the packing element 600, and this in the following manner. As illustrated by FIGS. 34a and 34b, a cavity 730 is formed in the product forming surface of the lateral molding die 635, and this by way of example, After closing of all the molding dies, the solution foam resin is poured and the cover sheet 612 is maintained in intimate contact with the inner wall surface of the cavity 730 under the pressure of the carbon dioxide generated when the resin materials transform into foam.

   After hardening of the resin materials, the area 624 complementary to the cavity 730 is formed.



   With the present invention, as described above, the covering sheet is produced in a shape complementary to that of the trim element for the motor vehicle to be produced and having an embossed surface, the first component, as that supports or brackets is molded into the cover sheet during the first foaming process, and the second component, such as a conduit, box, etc., is molded into the cover sheet during the second foaming process, thereby producing the trim element for a motor vehicle.

   As the packing element is formed in one piece as a unitary product, the entire manufacturing process is carried out automatically much more efficiently than would be the case if components, such as consoles , supports, conduits, boxes, etc. were fixed by screws or similar means. The the-

  <Desc / Clms Page number 48>

 unit lining will not make noise during the movement of the motor vehicle against the traditional lining elements which consist of separate sections joined together, and the unit lining element according to the invention will have a rich, sophisticated appearance and massive, since there are no joints or steps on the surfaces.

   The packing element is also light in weight since its desired rigidity is provided by foam bodies instead of cores.



  * In addition, all of the molding dies, after molding of a covering sheet, is opened by moving the chassis sheep carrying the gripping means which tighten the covering sheet, at a speed lower than that of the sheep. now forging the movable die, so that the finished cover sheet can automatically be removed from the mold die assembly. Since the cover sheet is automatically separated in synchronism with the operation of the cover sheet forming device, this cover sheet can be removed very effectively.



   The loading trolley for loading the covering sheet and the unloading trolley for discharging this sheet can alternatively be moved towards and out of the covering sheet forming device along the common rails provided on the chassis sheep. In this way, the feed mechanism of the cover sheet is of compact dimensions.



   The unloading cart for unloading the cover sheet has templates to prevent this cover sheet from being deformed immediately after it has been removed from the set of molding dies. As a result, the cover sheet can be safely discharged without damage.



   In addition, a blank of synthetic resin cover sheet, which has been heated, is clamped between the first and second molding dies. Then pressurized air is fed into one of the molding dies to press the blank against the other molding die, and then that blank is drawn under

  <Desc / Clms Page number 49>

 vacuum to the other molding die, so that the pressure applied to the blank is made substantially uniform. Therefore, an embossed design can be transferred to the blank regardless of the configurations of the molding dies. The first and second molding dies have a very large number of ventilation or communication holes. This arrangement is effective in preventing a foam resin material from being locally crushed.

   Up to now, auxiliary communication holes provided in one of the molding dies have been responsible for local crushing of the foam resin material. The packing element produced by the present invention is also of high quality since the laminated synthetic resin layers cannot be peeled off. The forming device itself is small in size since it incorporates the pressurizing means and the suction means.



   With the device for placing a covering sheet, this covering sheet is pressed into close contact with the molding dies by pressure elements which are aligned with the zones of a complex shape or the narrow zones of the cover sheet. Consequently, the cover sheet can be adjusted in place more easily and more securely than in the case of the traditional method where the cover sheet is pressed against the molding dies by the operator's fingers.

   As the cover sheet can be precisely adjusted in place against the molding dies, even in narrow areas which are not accessible to the operator's fingers, it is possible to fabricate the packing member in a manner such that it does not have folds and superficial displacements and that it is of high quality.



   The cover sheet is attracted and held by the cover sheet positioning device by the intervention of the suction means thereof. Therefore, the surface configuration of the cover sheet can be confirmed by the operator before this cover sheet is put into the set of molding dies. This allows the element

  <Desc / Clms Page number 50>

 packing to be manufactured more precisely.



   The packing member of the present invention is composed of a synthetic resin cover sheet and foam resin body laminated on the cover sheet. The foam resin bodies comprise a first foam body comprising positioning elements for positioning a component to be mounted on the packing element, and a second foam body in which the component which is placed by is embedded. positioning elements. Consequently, even if the component to be installed is of complex shape, it can be securely mounted in place without displacement of position, and the manufacturing process is simplified since the component does not have to be attached later.

   Joint elements interposed between the component and the first foam body are effective in preventing leakage of the resin material while it is being transformed into foam. This also results in a high quality packing element.



   As the component is installed using the foam resin bodies and elastic gasket elements, instead of using fixing means, such as screws, the finished packing element does not produce unwanted noise which would otherwise be caused by the fasteners when they come loose.



   In addition, the cover sheet which has been brought to a stretched configuration is kept in intimate contact with certain shaping elements existing on the product forming surface, under the pressure of the carbon dioxide generated when the resin material is transformed into foam. . The shaping elements include a sliding core and a cavity for forming convex and concave parts on the packing element. Since the precision of the shaping of the cover sheet to bring it to the desired configuration before additional layers of resin are transformed into foam on the cover sheet need not be very high, the cost of the dies of molding for the conformation of the cover sheet can be reduced.

   The cover sheet can

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 then be placed without precision in all of the molding dies of the forming devices and then be brought automatically into intimate contact with the female molding die under the pressure of carbon dioxide generated during the foaming process. As a result, the cover sheet can be easily handled when it is to be placed in the set of molding dies. A relatively complex form of product can be achieved by the sliding core in the female mold element. Different product designs can easily be envisioned using different sliding cores.



   Although certain preferred embodiments have been described and illustrated, it should be understood that many changes and modifications can be made without departing from the scope of the appended claims.


    

Claims (41)

 CLAIMS 1. Packing element intended to be used in a motor vehicle, characterized in that it comprises a covering sheet (12) having a surface having an embossed design, a first foam body (14) disposed on the other surface of the cover sheet, a first component (16) being partially embedded in this first foam body; a second foam body (18) disposed on this other surface and / or on the first foam body, a second component (20) being partially embedded in this second foam body; the cover sheet, the first foam body and the second foam body being made in one piece in the form of a unitary construction.  2. Packing element according to claim 1, characterized in that the first component is a magnetic metallic element, and in that the second component is made of a resin material.  3. Packing element according to claim 1, characterized in that the first and second foam bodies are each made of a resin of hard urethane foam.  4. Lining element according to claim 1, characterized in that the covering sheet is in the form of a composite sheet comprising a sheet imitating resin leather and a sheet of polyolefin foam, the sheet imitating leather and the sheet foam being superimposed.  5. A packing element intended for use in a motor vehicle, comprising: a synthetic resin covering sheet; a first foam body disposed on this cover sheet and comprising a positioning element for the positioning of a component; a second foam body in which the component put in place by this positioning element of the first foam body is at least partially embedded; the cover sheet, the first foam body and the second foam body being made in one piece in the form of a unitary construction.  <Desc / Clms Page number 53>    6. lining element according to claim 5, characterized in that it comprises a seal element interposed between the above component and the positioning element of the first foam body.  7. Packing element according to claim 6, characterized in that the seal element consists of an elastic element.  8. A method of manufacturing a trim element for use in a motor vehicle, comprising the following phases: the production of a cover sheet of a shape complementary to that of the trim element and having a surface with an embossed design; forming a first foam body on this cover sheet with a first component placed on this cover sheet and partially embedded in this first foam body; and forming a second foam body on this cover sheet and / or on the first foam body, a second component being placed and partially embedded in this second foam body.  9. The method of claim 8, characterized in that it further comprises the phase of removal by blowing a separating agent from the first foam body, after forming this first body.  10. The method of claim 8, characterized in that it further comprises the deburring phase of the second foam body after the formation thereof.  11. Method according to claim 8, characterized in that the first aforesaid component is made of a magnetic metallic material, the first foam body being formed by a first forming device comprising an upper molding die and a lower molding die, the aforesaid first component being attracted magnetically to the upper molding die by a magnet, the cover sheet being attracted to this lower molding die by suction means forming a vacuum.  12. Method according to claim 8, characterized in that the aforesaid second component is made of a resin material.  <Desc / Clms Page number 54>    13. Method according to claim 8, characterized in that the first foam body is formed in one piece with a rib and / or an attachment base for the establishment of the second component when the first foam body is formed .  14. The method of claim 8, characterized in that the first and the second foam body are each made of a resin of hard urethane foam.  15. The method of claim 8, characterized in that the cover sheet is in the form of a composite sheet comprising a resin sheet imitating leather and a polyolefin foam sheet, the sheet imitating leather and the foam sheet being superimposed.  16. A method of manufacturing a trim element for a motor vehicle, characterized in that it comprises the following phases: the production of a cover sheet of a shape complementary to that of the trim element and having a surface with an embossed design; forming a first foam body on this cover sheet, this first foam body comprising a positioning element for the positioning of a component; and forming a second foam body, the component put in place by the above positioning element being at least partially embedded in this body.  17. The method of claim 16, characterized in that a seal element is provided on the positioning element of the first foam body.  18. The method of claim 16, characterized in that the first foam body and / or the second foam body are made of a urethane foam resin.  19. A method of manufacturing a lining element intended for use in a motor vehicle, comprising the following phases: forming a covering sheet of a predetermined shape by pressing a sheet blank between a first fixed molding die and a second movable molding die supported on a die to be stamped; maintaining an exposed end of the cover sheet pressed between the first  <Desc / Clms Page number 55>  and the second molding die, gripping means being mounted on a chassis pin which is movable between the first and the second molding die;  elevating the stamping sheep and the chassis sheep so that the stamping sheep is moved at a lower speed than the chassis sheep, thereby separating the cover sheet from the second molding die; and mounting a component and a foam body on this cover sheet.  20. A method of manufacturing a trim element for a motor vehicle, comprising the following phases: pressing a preheated blank between a first and a second molding die; the supply of pressurized air to this blank by this first molding die or this second molding die; after a predetermined period of time has elapsed, the attraction of this blank by this second molding matrix or this first molding matrix, so as to conform the blank into a covering sheet; and mounting a component and a foam body on this cover sheet.  21. The method of claim 20, characterized in that it further comprises the phase of transferring a predetermined pattern to a surface of this blank when the latter is shaped into the covering sheet.  22. The method of claim 20 or 21, characterized in that the blank consists of a laminated body of synthetic resin.  23. A method of manufacturing a trim element usable in a motor vehicle, comprising the following phases: forming a cover sheet of a shape complementary to that of the trim element and having a surface comprising a embossed design; the establishment of this cover sheet in all of the molding dies having a cavity; pouring a foam resin into the cavity of all of the molding dies;  bringing the cover sheet into contact with a shaping element of a product forming surface of the above-mentioned assembly of the dies  <Desc / Clms Page number 56>  molding, which defines said cavity, under a pressure produced by this foam resin when it is transformed into foam, to thereby produce a local deformation of the cover sheet by said shaping element; and adding a configuration complementary to that of the shaping element to the above cover sheet when the foam resin is cured.  24. The method of claim 23, characterized in that the aforesaid shaping element comprises a sliding core intended to add a hollow as above configuration to the aforementioned covering sheet.  25. The method of claim 23, characterized in that the shaping element comprises a cavity intended to add a range as aforesaid configuration to the aforementioned covering sheet.  26. A system for manufacturing a trim element for a motor vehicle, comprising a covering sheet forming device, intended to form a covering sheet of a predetermined shape by pressing a sheet blank between a first and a second molding die, said cover sheet forming device comprising: a fixed plate for supporting the first molding die; a stamping sheep, movable vertically and supporting the second molding die; a chassis sheep vertically movable between the aforementioned fixed plate and the stamping sheep; and gripping means for gripping an exposed end of the cover sheet when the first and second molding dies are brought together to press this sheet blank.  27. The system of claim 26, characterized in that the gripping means comprise a series of clamping mechanisms each comprising a fixed clamping arm and a clamping arm movable relative to this fixed clamping arm, the clamping arm fixed and the movable clamping arm having ends intended to grip the covering sheet, these clamping mechanisms being arranged opposite the first and second molding die and being movable towards and away from them.  <Desc / Clms Page number 57>    28. The system of claim 26 or 27, characterized in that the chassis sheep comprises first rails extending horizontally and second rails connected to the first and extending outside the cover sheet forming device, and comprising in addition to a loading trolley intended for loading the sheet blank and a movable unloading trolley along the first aforementioned rails for discharging the covering sheet which is separated from the first and second molding die, these loading and unloading being movable back and forth towards and away from the aforesaid device for forming a covering sheet, along the first aforementioned rails.  29. System according to claim 28, characterized in that it further comprises means maintaining the configuration, on the unloading carriage to prevent the covering sheet from being deformed when it is separated from the first and from the second molding die.  30. System for manufacturing a trim element for a motor vehicle, characterized in that it comprises a covering sheet forming device, intended to form a covering sheet by pressing, pressurizing and attracting a sheet blank between a first and a second molding die, each of this first and second molding die comprising: a first porous layer having a series of very small holes and receiving temperature control conduits; a second porous layer comprising a series of very small holes and attached as a reinforcing layer to the above-mentioned first porous layer; at least one of this first and of this second molding matrix comprising a porous electroformed body disposed on the aforesaid first porous layer.  31. System according to claim 30, characterized in that it further comprises a pressure tank for pressurizing the sheet blank and a vacuum tank for attracting this sheet blank under the effect of vacuum.  32. System according to claim 30, characterized in that the porous electroformed body has a grainy surface  <Desc / Clms Page number 58>  giving a leather look.  33. System for manufacturing a trim element for a motor vehicle, comprising a covering sheet positioning device for placing a covering sheet of a predetermined shape in a set of molding dies to form a foam body forming part of the cover sheet, this device for positioning the cover sheet comprising: a frame; and a series of pressing elements supported on this chassis and of a shape complementary to that of the different zones of all of the molding dies, of pressure supported on this chassis and of a shape complementary to that of all of the dies molding.  34. System according to claim 33, characterized in that the chassis comprises a resin pipe, the device for positioning the cover sheet further comprises a profiled element of a shape essentially complementary to that of all the matrices of molding, the aforementioned pressure elements being supported on this profiled element.  35. System according to claim 33 or 34, characterized in that each of the pressure elements is made of a urethane elastomer.  36. System according to claim 34, characterized in that the profiled element has a skeleton of a shape essentially complementary to that of the cover sheet, the device for positioning the cover sheet further comprising support conduits in resin interconnecting this profiled element and this chassis.  37. System according to claim 34, characterized in that the profiled element is of a shape essentially complementary to that of the reverse side of the cover sheet, this profiled element and this frame being directly joined to one another .  38. System according to claim 37, characterized in that the profiled element has an opening for discharging air from the zone between this profiled element and the covering sheet.  <Desc / Clms Page number 59>    39. System according to claim 33, characterized in that each of the pressure elements comprises suction means for attracting the cover sheet under the effect of the vacuum.  40. System according to claim 39, characterized in that the suction means comprise a first conduit connected to a vacuum pump, and a second conduit, one end of which communicates with a suction hole defined in each pressure element, while that the other end is connected to the first conduit.  41. System according to claim 40, characterized in that it further comprises a layer of porous resin interposed between the aforementioned suction hole and the aforementioned second conduit.