CN115087533B

CN115087533B - Method for manufacturing vehicle cover

Info

Publication number: CN115087533B
Application number: CN202180012426.7A
Authority: CN
Inventors: 邦雅曼·凯内尔
Original assignee: Faurecia Interieur Industrie SAS
Current assignee: Faurecia Interieur Industrie SAS
Priority date: 2020-02-03
Filing date: 2021-02-03
Publication date: 2024-05-07
Anticipated expiration: 2041-02-03
Also published as: WO2021156279A1; CN115087533A; FR3106773A1; ES2925601A2; ES2925601R1; FR3106773B1

Abstract

A method of manufacturing a vehicle cover, comprising providing identical cover parts (4) and manufacturing a first vehicle cover (2) based on these covers (4), which is provided with a molded part (6) on a front face (4A) of its cover part (4), and a second vehicle cover (15) which has no molded part (6) on the front face (4A) of its cover part (4), each first vehicle cover (2) comprising a perforating step of perforating injection holes (14) through the cover part (4); positioning the cover part (4) in a mould (46); and injecting a molding material into the mold on the rear face (4B) side of the cover member (4) such that the molding material passes through the injection hole (14) to form a molded portion (6) on the front face (4A) of the cover member (4).

Description

Method for manufacturing vehicle cover

Technical Field

The present invention relates to the field of vehicle, in particular motor vehicle hoods.

Background

US4783298a relates to the manufacture of automotive parts, including molded products manufactured by the technique known as "sheet molding compound" (or SMC), i.e. by stacking and compression molding a plurality of resin sheets containing reinforcing fibers, and appearance coatings covering the entire front face of the molded product. It proposes a die for compression molding a molded product, the die further comprising a punch for punching an injection hole in the molded product; and an injection device for injecting a coating material into the mold at a rear side of the molded product, the coating material passing through the injection hole and covering a front of the product to form an exterior coating. In particular, the coating material is a two-component thermosetting resin that is mixed in a mixer prior to injection into the mold.

Disclosure of Invention

It is an object of the present invention to propose a method of manufacturing a vehicle cover, allowing to obtain a cover with high perceived quality, while limiting the manufacturing costs.

To this end, the invention proposes a method of manufacturing a vehicle cover, the method comprising providing identical cover parts, each cover part having a front face for viewing and a rear face opposite the front face, and manufacturing a first vehicle cover based on the cover parts, the first vehicle cover being provided with a molded part on the front face of the cover part thereof; and manufacturing a second vehicle cover having no molded portion on a front face of a cover member thereof, each first vehicle cover including a perforating step of perforating an injection hole in the cover member through the cover member between the rear face and the front face; placing the cover part in a mould, the mould and the front of the cover part forming a moulding cavity; and injecting a molding material into the mold at the rear side of the cover member such that the molding material passes through the injection hole and fills the molding cavity to form a molded portion located on the front side of the cover member.

Molding the molded portion on the front face via the hole through the cover member allows the molded portion to be achieved without degrading or affecting the front face and with high perceived quality.

The molding may constitute an additional operation which is carried out only on the cover part of the first vehicle cover and not on the cover part of the second vehicle cover, which allows the first and second vehicle covers to be easily obtained, for example for different decorations of the same vehicle model or for different vehicle models using the same cover part.

In particular embodiments, the method of manufacture includes one or more of the following optional features, which may be employed alone or in any technically possible combination:

The molded part covers only a part of the front face of the molded part;

the method comprises inserting a cannula into the injection hole prior to injection moulding the material;

The cover part and the cannula are configured such that the cannula mounted on the cover part is flush with the front face of the cover part.

The cannula is made up of two parts, including a front part and a rear part, configured to be inserted into the injection hole from the front side and the rear side, respectively, the front part and the rear part being fixed together by the injection hole;

The front and rear portions are secured to each other by a snap fit;

The front and rear parts each comprise tube sections which form a tube when the front and rear parts are joined;

At least one of the front and rear portions has a flange extending radially outwardly from an end of the tube section of said portion, the flange being adapted to bear against the front or rear face of the cap member when said portion is inserted into the injection hole;

The method comprises forming injection holes in the cover part, for example by punching;

the cover part has a vent for venting gases present in the molding cavity when the molding material is injected;

the molding material is a thermosetting polymer, such as polyurethane;

The injection pressure of the molding material into the mold is less than 500 bar, in particular less than 15 bar;

the cover part is laminated and comprises a plurality of layers stacked between the rear and front sides;

the cover part comprises a front layer defining a front face of the cover part and a rear layer defining a rear face of the cover part;

the cover part comprises at least one intermediate layer interposed between the rear layer and the front layer;

The mould has an injection channel for injecting the moulding material through an injection hole, the injection channel leading to an injection outlet which is at least partially offset with respect to a front opening through which the injection hole opens onto the front face of the cover part;

The invention also relates to a set of vehicle hoods made on the basis of identical hood parts, each hood part having a front face for visualization and a rear face opposite the front face, the set of hoods comprising a first vehicle hood identical to each other and a second vehicle hood identical to each other; the first vehicle hoods are different from the second vehicle hoods in that each first vehicle hood is provided with a molded portion formed at a front face of the hood part, and each second vehicle hood is free of such a molded portion.

Drawings

The invention and its advantages will be better understood by reading the following description, given by way of non-limiting example only, with reference to the accompanying drawings, in which:

FIG. 1 is a schematic cross-sectional view of a vehicle cover formed from a cover part and a molded part located on the front face of the cover part;

FIG. 2 is a schematic cross-sectional view of a second vehicle cover formed from the same cover component as the first vehicle cover of FIG. 1, but without molded portions;

FIG. 3 is a schematic cross-sectional view of a cutting tool for cutting injection holes in a cap member;

FIG. 4 is a schematic cross-sectional view of the cap component showing the installation of the cannula in the injection hole;

FIG. 5 is a schematic cross-sectional view of a mold for molding a molded portion on the front face of the cover part to obtain a first vehicle cover;

Fig. 6 shows a vehicle manufacturing method by using a first vehicle cover and a second vehicle cover made of the same cover part, these trim pieces, the cover part of the first vehicle cover being decorated with molded parts and the cover part of the second vehicle cover being devoid of molded parts;

Fig. 7 is a schematic cross-sectional view of a molding part showing an injection channel of the molding part and a molding part applied against the molding part.

Detailed Description

The first vehicle cover 2 shown in fig. 1 is, for example, a motor vehicle cover.

The first vehicle cover 2 is, for example, a center console cover, an instrument panel cover, a door lining cover, a seat cover, an armrest cover, a ceiling cover, a glove box cover, or the like.

The first vehicle cover 2 includes a cover member 4 having a front face 4A for viewing and a rear face 4B opposite the front face 4A.

The first vehicle cover 2 comprises a moulded portion 6 which at least partially covers the front face 4A of the cover part 4.

In the exemplary embodiment, the molded portion 6 only partially covers the front face 4A of the cover member 4. In other words, the molded portion 6 covers only a portion of the front face 4A of the cover member 4.

One area of the front face 4A of the cover member 4 is covered by the molded portion 6, and another area of the front face 4A of the cover member 4 is not covered by the molded portion 6.

For example, the molded portion 6 is decorative. Such a moulded part has no other function than to decorate the cover part 4. In the exemplary embodiment, the molded portion 6 forms a decorative protrusion on the front face 4A of the cover member 4.

In the exemplary embodiment, the cover member 4 is multi-layered. Comprising a front layer 8 defining a front face 4A and a rear layer 10 defining a rear face 4B, and optionally at least one intermediate layer 12 interposed between the front layer 8 and the rear layer 10.

The front layer 8 is the visible layer of the cover part 4. The front layer 8 defines the visual appearance of the first vehicle cover 2.

The front layer 8 is made of, for example, PVC (polyvinyl chloride), TPU (thermoplastic polyurethane), TPO (unvulcanized thermoplastic elastomer), natural or synthetic leather or TEP (plastic-coated fabric), the coating plastic of which is PVC, TPU, TPO, for example.

The rear layer 10 is, for example, a structural layer of the cover member 4. In this case, the rear layer 10 defines a curve, i.e. the shape of the cover part 4. Advantageously, the cover part 4 has a three-dimensional shape.

In the exemplary embodiment in which the cover member 4 includes the intermediate layer 12, the intermediate layer 12 is configured, for example, to impart a soft touch to the cover member 4.

The term "soft touch" means that the front layer 8 is deformable upon touching, i.e. can be deformed in a sensitive manner when the front layer 8 is pressed with a finger.

For this purpose, the intermediate layer 12 is, for example, foam, gel or three-dimensional fabric. In certain example embodiments, the intermediate layer 12 is PUR (polyurethane) foam.

In another exemplary embodiment, the cover part 4 does not comprise an intermediate layer 12. Which comprises only a front layer 8 and a rear layer 10.

In another embodiment, the cover part 4 is single-layered. Formed from a single layer of material defining a front face 4A and a rear face 4B.

For example, a single layer of cover member 4 is made of a material that imparts a hard feel to cover member 4, i.e., cover member 4 does not deform in a sensitive manner upon touch.

For example, the single-layer cover part 4 is made of a plastic material, whether or not filling is performed. The plastic material is for example polypropylene. If necessary, the filler comprises fibers, in particular natural or synthetic fibers.

The cover member 4 can be used without the molded portion 6, in other words, the cover member 4 constitutes a vehicle cover that can be directly used without adding the molded portion 6.

The molded portion 6 is additionally provided, for example, to change the appearance of the cover member 4.

Fig. 2 shows a second vehicle cover 15 formed from the same cover part 4 as the first vehicle cover 2.

The second vehicle cover 15 differs from the first vehicle cover 2 in that it has no molded portion 6. The front face 4A of the cover member 4 of the second vehicle cover 15 is free. The second vehicle cover 15 is arranged to be mounted in the vehicle in such a way that there is no moulded part 6 on the front face 4A.

The second vehicle cover 15 here comprises a cover part 4 with a front layer 8, a rear layer 10 and an intermediate layer 12.

The first vehicle cover corresponds, for example, to a finish of a vehicle model, and the second vehicle cover 15 corresponds to a finish of the same vehicle model or of another vehicle model.

Fig. 3 to 5 show steps of a manufacturing method which allows the hood part 4 to be equipped with a molded part 6 to obtain the first vehicle hood 2.

The method of manufacture comprises providing a cover part 4 initially without a moulded part 6.

For example, the cover part 4 is received or manufactured in a known manner.

For example, when the cover member 4 comprises multiple layers, the cover member 4 is made, for example, by stacking layers or by molding an intermediate layer 12 between the front layer 8 and the rear layer 10.

When the cover part 4 is made in the form of a single layer of material, it is made, for example, by moulding, in particular by injection moulding or compression moulding.

As shown in fig. 3, the manufacturing method includes, for example, punching holes in the cover member 4 to form injection holes 14 through the cover member 4.

The injection hole 14 passes through the cover member 4 throughout the thickness of the cover member 4 by opening at the front face 4A and the rear face 4B of the cover member 4.

The injection hole 14 is made by punching, for example. For example, the punching is carried out in a punching tool 16 comprising a base body 18 which is able to receive the cover part 4; and a punch 20 movable relative to the base 18 and carrying a punch element 22 arranged to pierce the injection hole 14 by bringing the punch 20 and the base 18 close together.

Optionally, the cover part 4 comprises a vent 24 allowing venting of gas when the molded part 6 is molded onto the cover part 4.

In this case, in the exemplary embodiment, the method of manufacture includes perforating to form drain 24, such as by punching.

As shown in fig. 3, the drain port 24 extends through the cover member 4, for example, between the front face 4A and the rear face 4B.

Advantageously and as shown in fig. 3, the injection hole 14 and the discharge port 24 are perforated simultaneously in the same perforation step.

For example, the injection hole 14 and the discharge port 24 are punched simultaneously with the punching tool 16. In fig. 3, the punch 20 has an additional punching element 25 for the perforation discharge 24.

As shown in fig. 4, the method of manufacture may optionally include installing a cannula 26 in the injection hole 14. The cannula 26 is configured to direct molding material through the injection hole 14 when molding the molded portion 6.

The cannula 26 includes a tube 28 that optionally provides a flange at one or each of the ends, each flange projecting radially outwardly from the tube 28 to rest against either the front face 4A or the rear face 4B of the cover member 4.

The cannula 26 has, for example, a front flange 30 which rests on the front face 4A of the cover part 4.

Advantageously, cannula 26 is configured to be flush with front face 4A. This avoids the formation of protrusions on the front face 4A which could impair the perceived quality of the user.

Alternatively, when the front flange 30 is provided, the front face 4A has, for example, a void 32 provided around the injection hole 14 and configured to receive the front flange 30, which is thus flush with the front face 4A.

The depth of the void 32 is preferably at least equal to the thickness of the front flange 30.

In a variant, the front face 4A does not have such a recess receiving the front flange 30.

In this case, when the intermediate layer 12 is provided, the intermediate layer 12 may be compressed, for example, under the stress of the front flange 30 of the cannula 26.

The cannula 26 has, for example, a rear flange 34 which rests on the rear face 4B of the cover part 4.

In the example of implementation, the cannula 26 is formed of two parts, a front part 36 and a rear part 38, which are assembled through the injection hole 14 to form the cannula 26 and to mount the cannula on the cover part 4.

For example, the front portion 36 and the rear portion 38 are configured to snap-fit to each other by approaching each other. Accordingly, inserting the front portion 36 and the rear portion 38 into the injection hole 14 from the front face 4A side and the rear face 4B side of the cover member 4, respectively, allows the front portion 36 and the rear portion 38 to be fixed to each other while the cannula 26 is mounted on the cover member 4.

In the exemplary embodiment, forward portion 36 includes a forward tube section 40 and, optionally, forward flange 30, and aft portion 38 includes an aft tube section 42 and, optionally, aft flange 34. The front and rear tube sections 40, 42 are configured to be connected to one another, such as by being secured to one another by a snap fit, to form the tube 28.

As shown in fig. 5, the cover member 4 equipped with the injection hole 14 in which the cannula 26 is mounted and optionally with the discharge port 24 is positioned in a mold 46 to mold the molded portion 6 on the front face 4A of the cover member 4 by injecting a molding material through the injection hole 14.

The mold 46 has a first mold portion 48 and a second mold portion 50 arranged to receive the cover member 4 therebetween while defining a molding cavity 52 with the front face 4A of the cover member 4 to mold the molded portion 6.

The first mould part 48 has a receiving surface 54 to receive the cover part 4, in particular the rear face 4B of the cover part 4.

The second mold portion 50 has a molding surface 56 to define a molding cavity 52 with the cover member 4, in particular with the front face 4A of the cover member 4.

The mold 46 has an injection device 58 to inject molding material into the molding cavity 52.

The injection device 58 has an injection channel 60 which opens onto the receiving surface 54 through an injection outlet 62, preferably substantially facing the injection hole 14 when the cover part 4 is positioned on the receiving surface 54.

Advantageously, the cover part 4 and the receiving surface 54 have complementary positioning projections which allow positioning the cover part 4 on the receiving surface 54, in particular such that the injection outlets 62 substantially face the injection holes 14.

The positioning projections comprise, for example, pins 64 provided on the cover member 4 and corresponding apertures 66 provided in the receiving surface 54, each aperture 66 being arranged to receive a respective pin 64.

Alternatively, the mold 46 may include a retaining device (not shown) configured to generate a force that retains the cover member 4 against the receiving surface 54. The retaining means for example comprises one or more suction cups and/or suction systems to create a back pressure between the cover member and the receiving surface 54.

Optionally, when positioning the cover part 4 in the mould 46, an adhesive and/or foam may be provided between the cover part 4 and the receiving surface 54 around the injection outlet 62 and/or the discharge opening 63 on the receiving surface 54 via which the optional discharge channel 65 leads to the discharge opening 24 facing the cover part 4 to provide a sealing between the cover part 4 and the receiving surface 54 around the injection opening and/or the discharge opening 63.

Optionally, the mold 46 further includes a heating system (not shown) configured to heat the first mold portion 48 and/or the second mold portion 50 to facilitate material injection.

In the exemplary embodiment in which the cover member 4 comprises a single layer defining a rigid substrate, the heating system configured to heat at least the second mold portion 50 allows the cover member 4 to locally melt at the contact point between the cover member 4 and the second mold portion 50, which in particular allows for improved sealing of the molding cavity 52.

This also allows the first vehicle cover 2 to obtain a pleasing appearance at the intersection between the molded portion 6 and the uncovered and visible portion of the front face 4A of the cover member 4.

In an embodiment example, the closing of the mould 46 for moulding of the moulded part 6 is performed in two steps, namely a first closing step of the mould 46, which is only arranged to locally melt the material of the cover part 4 without moulding the moulded part 6, followed by opening of the mould 46 and then a second closing step of the mould 46, this time for actual moulding of the moulded part 6.

The molding of the molded part is effected in a first closing step of the mold or in a subsequent second closing step of the mold.

In an embodiment, which is particularly suitable when the front face 4A of the cover part 4 is textured, the front face 4A is defined by a front layer of a single-or multi-layer molded part forming the cover part, the single-or front layer being heated, for example by infrared radiation, in order to avoid appearance defects at the edges of the molded part 6, and then being pressed by closing the mold 46 when cooling. This serves to smooth the texture at the front face 4A/second mould part 50 interface, which allows a clear demarcation at the edge of the moulded part 6.

In an exemplary embodiment, the molding material includes a plurality of components to be mixed to effect molding.

The molding material is, for example, a two-component thermosetting resin.

In this case, the injection device 58 comprises, for example, a mixer 68 to mix the components of the molding material. The mixer 68 provides a mixture of components to the injection channel 60.

Molding by injection of molding materials comprising a plurality of components, in particular two components, which react during molding is referred to in the english language as "reaction injection molding" or the corresponding acronym "RIM".

The heating system of the possible molds 46 configured to heat at least the second mold portion 50 defining the molding cavity 52 allows the components of the multicomponent molding material to react.

Advantageously, the second mold portion 50 has a sealing element 70 located at the periphery of the molding surface 56 and configured to be in sealing contact with the front face 4A of the cover member 4 when the mold 46 is closed. This allows to define a moulding cavity 52 together with the area in the cover part 4 for being covered by the moulding portion 6.

For example, the sealing element 70 is in the form of a peripheral lip or peripheral edge protruding from the molding surface 56 of the second mold portion 50.

For example, the thickness of such a peripheral lip or such a peripheral edge (measured in a direction parallel to the plane in which the cover part 4 extends) is between 0.1mm and 1mm, preferably between 0.4mm and 0.6 mm.

For example, the height of such a peripheral lip or such a peripheral edge (corresponding to the distance between the bottom of the molding surface 56 and the end of the peripheral lip or peripheral edge and measured in a direction perpendicular to the plane in which the cover part 4 extends) is between 1mm and 5mm, preferably between 1.5mm and 3 mm. The thickness of the moulded portion 6 is equal to the height of the peripheral lip or edge.

In an example, the sealing element 70 is configured against the front face 4A to deform it or more specifically compress the intermediate layer 12 to ensure sealing.

The interference between the sealing element 70 and the front face 4A is for example between 0.2 and 5mm, preferably between 0.2 and 2 mm. The greater the thickness of the intermediate layer 12, the greater the interference can be enhanced to enhance sealability.

The mold 46 includes a closure system 72 configured to close the mold 46 by approaching the second mold portion 50 to the first mold portion 48 while the first mold portion 48 is sealingly against the front face of the cover member 4.

In the illustrated example, the closure system 72 includes a first closure portion 74 carrying the first mold portion 48 and a second closure portion 76 carrying the second mold portion 50, and at least one actuator configured to bring the first closure portion 74 and the second closure portion 76 into proximity with each other to close the mold 46.

Advantageously, in the exemplary embodiment, closure system 72 includes a force adjustment device 78 that is configured to adjust a force that urges second mold portion 50 against front face 4A of cover member 4.

This allows to avoid marks on the front face 4A of the cover part 4 due to the abutment of the second mould part 50 against the front face 4A of the cover part 4, which would have an adverse effect on the perceived quality of the cover part 4.

The force adjustment device 78, for example, includes at least one spring to adjust the proximity force exerted on the first and second mold portions 48, 50.

In the illustrated example, the force adjustment means 78 are provided in the form of one or more springs 80, which are provided between the second closing portion 76 and the second mould portion 50.

Thus, the application of force by the second mould part 50 to the cover part 4 is limited, and excessive applied force is converted into elastic energy stored in one or more springs.

Each spring 80 is, for example, a coil spring, a plate spring, or an air spring as shown in fig. 5.

As shown in fig. 5, the manufacturing method includes injection molding a material. The molding material is injected into the mold 46 on the rear face 4B side of the cover member 4 and through the injection holes 14 on the front face 4A side of the cover member 4, more precisely via the cannula 26 into the molding cavity where the molded portion 6 is formed.

Preferably, the injection pressure of the molding material into the mold 46 is less than 500 bar, in particular less than 15 bar.

Furthermore, the injection rate is for example between 5g/s (g/s) and 20g/s, preferably between 5g/s and 10 g/s.

This allows limiting the risk of damaging the cover part due to the injection pressure of the molding material and limiting the abutment force of the mold part against the cover part.

As the molding material is molded, the molding material gradually fills the molding cavity.

The presence of the vent 24 allows the gas present in the mold cavity to vent as the mold material fills the mold cavity.

This allows mass moulding to be obtained by preventing, inter alia, air bubbles from being trapped in the moulding cavity.

In fig. 5, the second mold portion 50 is shown above the first mold portion 48. As a variant, the second mould part 50 is located below the first mould part 48. Thus, the vent 24 is located on the upper wall of the molding cavity 52 positioned between the second mold portion 50 and the front face 4A, and air present in the molding cavity 52 when injecting the molding material is easily vented through the vent 24 and, if present, the vent channel 65.

Once the molded portion 6 is sufficiently hardened, the mold 46 is opened and the cover member 4 is ejected from the mold 46.

Thus, a first vehicle cover 2 is obtained, which is formed by the cover part 4 provided with the molded part 6 on its front face 4A.

Further, as shown in fig. 6, the manufacturing method includes producing the first vehicle cover 2 and the second vehicle cover 15 based on the same cover member 4, the cover member 4 of the first vehicle cover 2 being decorated with the molded portion 6, and the cover member of the second vehicle cover 15 being devoid of the molded portion 6.

The vehicle manufacturing method includes manufacturing the same first vehicle covers 2 based on the cover member 4 provided with the molded portions 6 and mounting these first vehicle covers 2 in the vehicle, and manufacturing the second vehicle covers 15 based on the cover member 4 identical to the first vehicle covers but without the molded portions 6 and mounting the second vehicle covers 15 without the molded portions in the vehicle.

Thus, a set of vehicle hoods 86 made based on the same hood parts 4, each having a front face 4A for viewing and a rear face 4B opposite to the front face 4A, can be obtained, the set of vehicle hoods 86 comprising first vehicle hoods 2 identical to each other and second vehicle hoods 15 identical to each other, the first vehicle hoods 2 differing from the second vehicle hoods 15 in that each first vehicle hood 2 is provided with a molded part 6 on the front face 4A of the hood part 4, while each second vehicle hood 15 has no such molded part.

The molded portion 6 formed on the front face 4A of the cover member 4 allows the cover member 4 to be decorated. The molded portion 6 may be formed only on a portion of the front face 4A of the cover member 4, with another portion of the front face 4A of the cover member 4 remaining uncovered. Thus, the molded portion 6 can be formed with a valuable raised decoration.

According to an embodiment, the thickness of the molded portion 6 is constant. As a variant, the thickness of the molded portion 6 varies from one region to another to create a raised pattern. Such variable thickness results from the molding surface 56 having a shape complementary to the desired raised pattern.

Additionally, the molding surface 56 may be smooth or alternatively textured over all or a portion of the molding surface 56 to achieve a desired effect, such as a matte or shiny effect.

Injection of the molding material from the rear of the cover member 4 through the injection holes 14 to form the molding portion 6 at the front face 4A of the cover member 4 allows satisfactory results to be obtained without producing molding marks on the molding portion 6.

Providing the cannula 26 in the injection hole 14 allows the protective cover member 4 to be protected from damage due to molding.

In particular de1, this allows to prevent separation of the stack of cover parts 4, which may be caused by injection molding material under pressure through the injection holes 14.

The cannula 26, which is made of two parts fixed to each other by the injection hole 14, allows the cannula to be easily mounted on the cover part 4.

The cannula 26 flush with the front face 4A of the cover part 4 avoids the formation of projections that might affect the perceived quality of the first vehicle cover 2.

This limits the force with which the mould 46 must be kept closed in order to obtain tightness of the moulding cavity and thus limits the risk of damaging the front face 4A of the cover part 4, in particular when the moulded part 6 covers only a part of the front face 4A of the cover part 4. This also limits the risk of damaging the cover part 4 in the region of the injection hole 14.

The use of reactive injection molding (or RIM), which uses multicomponent, particularly two-component molding materials that react during molding, may allow injection at lower injection pressures than conventional injection.

Preferably, the cover member 4 of the second vehicle cover 15 has no injection hole 14 at a position where the cover member 4 of the first vehicle cover 2 is provided with the injection hole 14 for the injection-molded portion.

Preferably, the cover member 4 of the second vehicle cover 15 has no drain port 24 at a position where the cover member 4 of the first vehicle cover 2 is equipped with the drain port 24, when necessary.

The present invention is not limited to the above-described exemplary embodiments.

For example, in the illustrated example, the cover member 4 is provided with a drain port 24.

As a variant or alternatively and as shown in fig. 5, the second mould part 50 is configured to form a drain between the second mould part 50 and the front face 4A of the cover part 4.

In a particular embodiment, the sealing element 70 is provided with one or more discharge slots 82, each discharge slot 82 allowing to define a discharge with the front face 4A of the cover part 4.

Furthermore, preferably, the mold 46 and the cover part 4 are configured such that each injection hole 14 opens onto the front face 4A through a front opening 14A located near the edge of the molding cavity 52, i.e. here near the contact point between the second mold part 50 and the front face 4A of the cover part 4. This allows limiting the risk of bubble formation in the peripheral region of the moulded part 6.

Alternatively, as shown in fig. 5, the method of manufacture includes positioning the insert 84 in the mold cavity such that the insert 84 is overmolded by the mold portion 6 while the mold portion is being molded.

For example, the insert 84 is disposed in the molding cavity to be flush with the free face of the molded portion 6 when the molded portion 6 is completed. Thus, the insert 84 can be seen on this free face.

In the exemplary embodiment, insert 84 is a decorative insert, particularly a decorative icon.

In an exemplary embodiment, the insert 84 is a light guide.

In the exemplary embodiment, insert 84 is a haptic element for detecting a haptic interaction of a user with molded portion 6, such as a functional device for controlling a vehicle; proximity sensors, for example, for detecting when a user approaches his finger or hand; or a touch actuator for providing touch feedback to the user when the user touches the molded part 6. This allows the molded portion 6 to be given a function.

As shown in fig. 5, the insert 84 is for example arranged on the second mould part 50 such that it is flush with the free face of the mould part 6 after moulding, or on the front face 4A of the cover part 4 such that it is covered by the mould part 6 after moulding.

The use of the same cover part 4 to provide different versions (with or without moulded parts) allows limiting the production costs of the vehicle, while adjusting the perceived quality or providing the possibility of customization, in particular the decoration of the cover part by means of moulded parts.

Furthermore, it is also possible to provide different covers, which are formed on the basis of the same cover part 4, but are provided with different molded parts, which differ for example by the molding material (color, hardness, transparency.) and/or the shape thereof and/or by the addition or deletion of inserts 84.

Further, as shown in fig. 7, the injection hole 14 opens onto the front face 4A of the cover member 4 through the front opening 14A.

In an advantageous exemplary embodiment, the mold 46 and the cover part 4 are configured such that the injection outlet 62 of the injection channel 60 is at least partially offset with respect to the front opening 14A.

Thus, the injection outlet 62 does not face the front opening 14A of the injection hole 14. At least a portion of the injection outlet 62 does not face the front opening 14A. In a particular example, the entire injection outlet 62 does not face the front opening 14A.

This offset allows limiting the risk of defects occurring in front of the moulded part 6 due to shrinkage of the moulding material. This shrinkage is caused by the greater thickness of the molding material facing the injection channel 60 than the rest of the molded portion 6. In fact, at the injection hole 14, the thickness of the molding material is equal to the sum of the thickness of the molding portion 6 and the thickness of the cover member, while for the rest of the molding portion 6, the thickness is limited to the thickness of the molding portion 6.

Advantageously, the mold 46 and the cover member 4 are configured such that at least two thirds of the surface of the injection outlet 62 of the injection channel 60 is not aligned with the front opening 14A of the injection hole 14, preferably such that the entire surface of the injection outlet 62 of the injection channel 60 is not aligned with the front opening 14A of the injection hole 14.

In an exemplary embodiment, the mold 46 and the cover member 4 are configured such that the injection outlet 62 is offset relative to the front opening 14A by a distance E between 1mm and 3mm, in particular a distance of about 2mm, measured between a direction parallel to the plane in which the cover member 4 extends and the nearest edge of the injection outlet 62 and the front opening 14A.

To obtain the desired offset while allowing injection of material from the injection outlet 62 through the injection hole 14, the cover member 4 comprises, for example, a cavity 88 provided on the rear face 4B while being positioned such that the injection outlet 62 faces the cavity 88, the injection hole opening into the cavity 88 to receive the molding material introduced into the cavity 88.

Each cover part 4 (for producing the first vehicle cover 2 or the second vehicle cover 15) is provided with a cavity 88 which is provided in the rear face 4B and is not perforated, and each cover part 4 for producing the first vehicle cover 2 is perforated to form the injection hole 14. The cavity 88 in the rear face 4B of each cover part 4 for manufacturing the second vehicle cover 15 is not visible.

Claims

1. A method of manufacturing a vehicle cover, comprising providing identical cover parts (4), each cover part (4) having a front face (4A) for visualization and a rear face (4B) opposite to the front face (4A), and manufacturing, based on these cover parts (4), a first vehicle cover (2) provided with a molded part (6) on the front face (4A) of its cover part (4) and a second vehicle cover (15) without a molded part (6) on the front face (4A) of its cover part (4), each first vehicle cover (2) comprising a perforating step of perforating an injection hole (14) in the cover part (4), the injection hole passing through the cover part (4) between the rear face (4B) and the front face (4A); positioning the cover part (4) in a mould (46) forming a moulding cavity (52) with the front face (4A) of the cover part (4); and injecting a molding material into the mold on the rear face (4B) side of the cover member (4) such that the molding material passes through the injection hole (14) and fills the molding cavity (52) to form a molded portion (6) on the front face (4A) of the cover member (4), characterized in that,

The manufacturing method further comprises inserting a cannula (26) into the injection hole (14) before injecting the molding material, the cannula (26) being made of two parts including a front part (36) and a rear part (38), the two parts being configured to be inserted into the injection hole (14) from the front (4A) side and the rear (4B) side, respectively, the front part (36) and the rear part (38) being fixed together by the injection hole (14).

2. The manufacturing method according to claim 1, wherein the molded portion (6) covers only a portion of the front face (4A) of the cover member (4).

3. The manufacturing method according to claim 1 or 2, wherein the front portion (36) and the rear portion (38) are fixed to each other by snap-fitting.

4. The manufacturing method according to claim 1, wherein the front portion (36) and the rear portion (38) each comprise tube sections that form a tube when the front portion and the rear portion are joined.

5. The method of manufacturing according to claim 4, wherein at least one of the front portion (36) and the rear portion (38) has a flange extending radially outwardly from an end of the tube section of the portion, the flange being adapted to bear against the front or rear face of the cap member when the portion is inserted into the injection hole.

6. The manufacturing method according to claim 1, comprising forming the injection hole (14) in the cap member.

7. The manufacturing method according to claim 6, wherein the injection hole (14) is formed in the cap member by punching.

8. The manufacturing method according to claim 1, wherein the cover part (4) has a discharge opening (24) to discharge the gas present in the molding cavity when the molding material is injected.

9. The manufacturing method according to claim 1, wherein the molding material is a thermosetting polymer.

10. The method of manufacturing according to claim 9, wherein the thermosetting polymer is polyurethane.

11. The manufacturing method according to claim 1, wherein an injection pressure of the molding material into the mold is less than 500 bar.

12. The manufacturing method according to claim 11, wherein an injection pressure of the molding material into the mold is less than 15 bar.

13. The manufacturing method according to claim 1, wherein the cover part (4) is laminated and comprises a plurality of layers stacked between the rear face (4B) and the front face (4A).

14. The manufacturing method according to claim 1, wherein the mould (46) has an injection channel (60) for injecting the moulding material through the injection hole (14), the injection channel (60) leading to an injection outlet (62) which is at least partially offset with respect to a front opening (14A) through which the injection hole (14) leads onto the front face (4A) of the cover part (4).

15. A set of vehicle covers made on the basis of identical cover parts (4), each cover assembly having a front face (4A) for visibility and a rear face (4B) opposite to the front face (4A), the set of vehicle covers comprising first vehicle covers (2) identical to each other and second vehicle covers (15) identical to each other, the first vehicle covers differing from the second vehicle covers in that each first vehicle cover (2) is provided with a molding portion (6) formed on the front face of the cover part (4), the cover part (4) being provided with an injection hole (14) passing through the cover part (4) between the rear face (4B) and the front face (4A) of the cover part (4),

Characterized in that a cannula (26) is inserted into the injection hole (14), the cannula (26) being made of two parts comprising a front part (36) and a rear part (38), the two parts being configured to be inserted into the injection hole (14) from the front (4A) side and the rear (4B) side, respectively, the front part (36) and the rear part (38) being fixed together by the injection hole (14), the molded part (6) passing through the injection hole (14) via the cannula (26), each second vehicle cover (15) being devoid of such molded part (6).