EP3706973A1 - Method for producing a moulded plastic part with a grained outer surface of higher quality - Google Patents

Method for producing a moulded plastic part with a grained outer surface of higher quality

Info

Publication number
EP3706973A1
EP3706973A1 EP18801021.9A EP18801021A EP3706973A1 EP 3706973 A1 EP3706973 A1 EP 3706973A1 EP 18801021 A EP18801021 A EP 18801021A EP 3706973 A1 EP3706973 A1 EP 3706973A1
Authority
EP
European Patent Office
Prior art keywords
grained
cavity
tpe
matrix
skin
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP18801021.9A
Other languages
German (de)
French (fr)
Inventor
Bertrand CHATAGNIER
Arnaud BOURGET
Alain Jouglet
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Stellantis Auto SAS
Original Assignee
PSA Automobiles SA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by PSA Automobiles SA filed Critical PSA Automobiles SA
Publication of EP3706973A1 publication Critical patent/EP3706973A1/en
Pending legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/03—Injection moulding apparatus
    • B29C45/04—Injection moulding apparatus using movable moulds or mould halves
    • B29C45/0441—Injection moulding apparatus using movable moulds or mould halves involving a rotational movement
    • B29C45/045—Injection moulding apparatus using movable moulds or mould halves involving a rotational movement mounted on the circumference of a rotating support having a rotating axis perpendicular to the mould opening, closing or clamping direction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/42—Moulds or cores; Details thereof or accessories therefor characterised by the shape of the moulding surface, e.g. ribs or grooves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/16—Making multilayered or multicoloured articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/26—Moulds
    • B29C45/263—Moulds with mould wall parts provided with fine grooves or impressions, e.g. for record discs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/26—Moulds
    • B29C45/37—Mould cavity walls, i.e. the inner surface forming the mould cavity, e.g. linings
    • B29C45/372—Mould cavity walls, i.e. the inner surface forming the mould cavity, e.g. linings provided with means for marking or patterning, e.g. numbering articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2021/00—Use of unspecified rubbers as moulding material
    • B29K2021/003—Thermoplastic elastomers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material

Definitions

  • the present invention relates to a method of manufacturing a molded plastic part with external grained surface.
  • the interior trim of motor vehicles (and more particularly that of dashboards and doors) is generally provided by large plastic cladding elements comprising a rigid support conferring their shape and skin lining grained defining the outer surface of appearance (including color, texture and feel).
  • This skin colored in the mass and reproducing for example the appearance of leather or a geometric pattern, must also have good resistance to external aggressions it may suffer (scratches, exposure to chemical agents such as solvents, UV radiation , temperature variations, etc.).
  • such a covering element also comprises a layer of plastic foam interposed between the skin of coating and the rigid support to provide properties of flexibility and sound and heat insulation.
  • the skin When such a layer of foam is present, the skin must be made independently of the rigid support, in a compatible material on the one hand with the foam subsequently injected between the skin and the support, and on the other hand with the finishing lacquers deposited on the outer surface of this same skin.
  • the skin is for example obtained by a "slush-molding" process of depositing, on a matrix covered with a layer of nickel applied by electroplating and preheated, thermoplastic elastomer powder (TPE) or polyvinyl chloride (PVC) which, in contact with the hot surface of the matrix, will melt and cover it.
  • TPE thermoplastic elastomer powder
  • PVC polyvinyl chloride
  • the deck fittings intended to be attached to these load-bearing panels are produced by a conventional method of injecting a thermoplastic resin made of polypropylene ( PP) or ethylene / propylene (P / E) copolymer in a chemically grained steel mold.
  • PP polypropylene
  • P / E ethylene / propylene
  • DE 102006024263 A1 discloses a method of manufacturing a multilayer molded body in which a sheet made of a thermoplastic elastomer film applied to a textile is positioned against the matrix of a mold having a decorative pattern grained in negative.
  • the molding cavity of the mold is then closed and a plastic polymer is injected into this cavity so that the thermoplastic film is compressed against the grained matrix and deforms due to the heat transmitted by the injected material by adopting the decorative pattern.
  • the invention therefore aims to improve the level of perceived quality of plastic fittings to be reported for example on dashboards or door panels of a motor vehicle.
  • thermoplastic polymer into a molding cavity delimited by a punch and a first matrix so as to constitute a rigid support
  • the method according to the invention makes it possible to achieve, for a particularly reasonable investment and cost price, interior trim elements for a motor vehicle, and in particular for fittings for a dashboard carrying panel or interior door trim whose skin coating has a graining quality identical or at least very similar to that of the coating skin of such a carrier panel obtained by a much more expensive process such as "slush-molding" or PU spray.
  • This graining quality thus makes it possible to obtain a visual homogeneity of appearance on the entire dashboard or interior door trim.
  • said first thermoplastic polymer injected into said molding cavity to constitute said rigid support is chosen from polypropylene (PP), ethylene / propylene copolymer (P / E), acrylonitrile butadiene styrene (ABS), or a mixture of acrylonitrile butadiene styrene and polycarbonate (ABS / PC);
  • thermoplastic polymer is reinforced in natural or synthetic fillers
  • said first and second dies are made in the same metal block pivoted at 180 °;
  • thermoplastic elastomer such as, for example, a thermoplastic copolyester (TPE-E), a thermoplastic olefin (TPE-O), a thermoplastic polyurethane ( TPE-U) or a styrene block copolymer (TPE-S);
  • said step of injecting a second polymer is carried out according to a reaction injection molding technique; said second polymer injected into said overmoulding cavity to constitute said grained coating skin is polyurethane (PU); and or
  • said first matrix partially delimiting said molding cavity is chemically grained or electro-erosion so as to improve the mechanical strength of said grained coating skin on said support;
  • the invention also aims, in a second aspect, with a deck hardware component for a dashboard or interior door trim panel obtained by such a method.
  • said support has a thickness of between 1 and 5 mm, while that of said skin of coating is between 0.5 and 3 mm.
  • FIG. 1 shows a flow chart of the method according to the invention for manufacturing a multilayer molded body with textured outer surface
  • FIGS. 2A to 2C illustrate the different stages of implementation of the method according to the invention.
  • FIG. 3 shows a sectional view of a molded part obtained by the method according to the invention.
  • FIG. 2A illustrates a first step 100 of this method during which a first thermoplastic polymer is injected under pressure and under hot conditions via an injection molding machine not shown in a molding cavity CM delimited by a punch P and a first steel matrix Mi, so as to constitute a rigid support S.
  • Such an injection molding machine conventionally comprises a hopper for collecting thermoplastic resin granules and a heated motorized auger via which the granules coming from the hopper are conveyed in the form of an injectable viscous fluid. to an injection head fluidically connected to at least one nozzle B M formed in the punch P and opening into the mold cavity CM.
  • the first thermoplastic polymer constituting the rigid support is preferably chosen from polypropylene (PP), ethylene / propylene copolymer (P / E), acrylonitrile butadiene styrene (ABS), or a mixture of acrylonitrile butadiene styrene and polycarbonate (ABS / PC).
  • PP polypropylene
  • P / E ethylene / propylene copolymer
  • ABS acrylonitrile butadiene styrene
  • PC polycarbonate
  • this first thermoplastic polymer is advantageously reinforced in natural or synthetic fillers (for example lamellar mineral fillers such as talc or micro-fibrils and nano-mineral fibrils such as glass fibers etc.), for example up to 10 to 35% by weight.
  • natural or synthetic fillers for example lamellar mineral fillers such as talc or micro-fibrils and nano-mineral fibrils such as glass fibers etc.
  • the surface of this second matrix M 2 has a decorative pattern D grained negative by direct laser incision and imitating, for example, the surface appearance of the leather or carbon.
  • This technique of graining by a laser beam directly eroding the surface of the matrix M 2 and whose path is managed by a numerically controlled five-axis machine, allows to produce complex textures with a great fineness of detail and in a reproducible way.
  • the first and the second matrix Mi, M 2 are hollowed out of the same steel block pivoted 180 ° so as to simplify the mechanism for moving these matrices (a single arm associated with a jack can then ensure closing or opening of these two matrices).
  • a second polymer is then injected under heat and under pressure into the overmolding cavity CSM (step 300) so as to constitute a skin of coating R overmolded against the support S and having a grained external surface reproducing the decorative pattern D.
  • This second injection step is performed via a second injection molding machine, the injection head of which is fluidly connected to at least one nozzle B S M formed in the punch P and opening into the overmoulding cavity CSM.
  • the second polymer constituting the grained coating skin R is advantageously a thermoplastic elastomer (TPE) such as for example a thermoplastic copolyester (TPE-E), a thermoplastic olefin (TPE-O), a thermoplastic polyurethane (TPE-U) or a styrene block copolymer (TPE-S) such as SEBS, this family of polymers having good resistance to abrasion and can be easily tinted.
  • TPE thermoplastic elastomer
  • TPE-E thermoplastic copolyester
  • TPE-O thermoplastic olefin
  • TPE-U thermoplastic polyurethane
  • SEBS styrene block copolymer
  • the second injection step may also be carried out using a reaction injection molding technique (better known by the term “reaction injection molding” or "RIM").
  • This known technique consists in injecting into a molding cavity (in this case the overmoulding cavity) and via a mixing and injection head a mixture of two liquid components coming from two separate feed units and possibly associated with additives (such as, for example, a surfactant, a catalyst and / or a foaming agent). When in contact just prior to injection into the cavity, these two components chemically react exothermically with each other to form a polymer in liquid or foamed form.
  • additives such as, for example, a surfactant, a catalyst and / or a foaming agent
  • This chemical reaction also causes a significant increase in the pressure inside the cavity that pushes the polymer into all parts of the mold cavity.
  • the chemical reaction will form polyurethane in the form of foam which will be injected into the overmoulding cavity CSM to form the grained skin coating R.
  • the second die M 2 is removed and the workpiece is ejected from the mold (step 400).
  • the support S will have a thickness of between 1 and 5 mm, while that of the skin of coating R will be between 0.5 and 3 mm.
  • the table below shows several examples of pairs of polymers that can be combined to form such a molded external surface molded part.
  • the first matrix Mi partially delimiting the molding cavity CM is advantageously chemically grained or by electro-erosion ("Electric Discharge Machining" in English).

Abstract

The present invention concerns a method for producing a moulded plastic part with a grained outer surface, characterised in that it comprises the following sequence of steps: - injecting a first thermoplastic polymer into a moulding cavity delimited by a punch and a first die in order to constitute a rigid support (100); - removing said first die and replacing the latter with a second die having a decorative pattern negatively grained by direct laser incision and delimiting, with said punch and said rigid support, an overmoulding cavity (200); - injecting a second polymer into said overmoulding cavity so as to constitute a coating skin overmoulded against said support and having a grained outer surface reproducing said pattern (300); and - removing the second die and ejecting said moulded part (400).

Description

PROCEDE DE FABRICATION D'UNE PIECE PLASTIQUE MOULEE A SURFACE EXTERNE GRAINEE DE QUALITE SUPERIEURE. Domaine de l'invention  PROCESS FOR MANUFACTURING A MOLDED PLASTIC PIECE WITH EXTERIOR GRAIN SURFACE OF HIGHER QUALITY. Field of the invention
La présente invention concerne un procédé de fabrication d'une pièce plastique moulée à surface externe grainée.  The present invention relates to a method of manufacturing a molded plastic part with external grained surface.
Elle vise également un élément d'habillage intérieur de véhicule automobile obtenu par un tel procédé.  It also relates to a motor vehicle interior trim element obtained by such a method.
Arrière-plan de l'invention Background of the invention
L'habillage intérieur des véhicules automobiles (et plus particulièrement celui des tableaux de bord et des portières) est généralement assuré par des éléments d'habillage en matière plastique de grandes dimensions comportant un support rigide leur conférant leur forme ainsi qu'une peau de revêtement grainée définissant la surface extérieure d'aspect (notamment, la couleur, la texture et la sensation au toucher).  The interior trim of motor vehicles (and more particularly that of dashboards and doors) is generally provided by large plastic cladding elements comprising a rigid support conferring their shape and skin lining grained defining the outer surface of appearance (including color, texture and feel).
Cette peau, colorée dans la masse et reproduisant par exemple l'aspect du cuir ou un motif géométrique, doit présenter en outre une bonne résistance aux agressions extérieures qu'elle peut subir (rayures, exposition aux agents chimiques tels que les solvants, rayonnement UV, variations de températures, etc.).  This skin, colored in the mass and reproducing for example the appearance of leather or a geometric pattern, must also have good resistance to external aggressions it may suffer (scratches, exposure to chemical agents such as solvents, UV radiation , temperature variations, etc.).
Dans certains véhicules haut de gamme, un tel élément d'habillage comprend également une couche de mousse en matière plastique interposée entre la peau de revêtement et le support rigide pour apporter des propriétés de souplesse et d'isolation phonique et thermique.  In certain high-end vehicles, such a covering element also comprises a layer of plastic foam interposed between the skin of coating and the rigid support to provide properties of flexibility and sound and heat insulation.
Lorsqu'une telle couche de mousse est présente, la peau doit être réalisée indépendamment du support rigide, dans une matière compatible d'une part avec la mousse ultérieurement injectée entre la peau et le support, et d'autre part avec les laques de finition déposées sur la surface externe de cette même peau. De manière connue, la peau est par exemple obtenue par un procédé de « slush-molding » consistant à déposer, sur une matrice couverte d'une couche de nickel appliquée par électrodéposition et préalablement chauffée, de la poudre en élastomère thermoplastique (TPE) ou en polychlorure de vinyle (PVC) qui, au contact de la surface chaude de la matrice, va fondre et recouvrir celle-ci. When such a layer of foam is present, the skin must be made independently of the rigid support, in a compatible material on the one hand with the foam subsequently injected between the skin and the support, and on the other hand with the finishing lacquers deposited on the outer surface of this same skin. In known manner, the skin is for example obtained by a "slush-molding" process of depositing, on a matrix covered with a layer of nickel applied by electroplating and preheated, thermoplastic elastomer powder (TPE) or polyvinyl chloride (PVC) which, in contact with the hot surface of the matrix, will melt and cover it.
Il est également connu de réaliser cette peau par un procédé PU spray consistant à pulvériser un film mince de polyuréthane élastomère sur la surface d'un moule, ce film étant ensuite décollé sous la forme d'une peau après réticulation.  It is also known to make this skin by a PU spray process consisting of spraying a thin film of elastomeric polyurethane on the surface of a mold, this film then being peeled off as a skin after crosslinking.
Ces deux procédés offrent une grande précision de moulage (finesse des détails du grainage) ainsi qu'un contrôle des jeux satisfaisant (faibles rayons), ce qui permet d'obtenir d'excellents résultats du point de vue de la qualité perçue avec un ressenti visuel et sensoriel particulièrement riche pour les usagers.  These two processes offer a high precision of molding (fineness of the details of the graining) as well as a satisfactory control of the games (weak rays), which makes it possible to obtain excellent results from the point of view of the quality perceived with a feeling visual and sensory particularly rich for users.
La mise en œuvre de ces procédés étant particulièrement coûteuse, celle-ci est généralement réservée à la fabrication de pièces de grandes dimensions telles que les panneaux porteurs de planches de bord ou d'habillage de portières.  The implementation of these methods being particularly expensive, it is generally reserved for the manufacture of large parts such as panels bearing dashboards or door trim.
Les éléments d'accastillage destinés à être rapportés sur ces panneaux porteurs (tels que par exemple, les enjoliveurs ou encore les couvercles de boîtes à gants) sont quant à eux réalisés par un procédé classique d'injection d'une résine thermoplastique en polypropylène (PP) ou en copolymère éthylène/propylène (P/E) dans un moule acier grainé chimiquement.  The deck fittings intended to be attached to these load-bearing panels (such as, for example, hubcaps or glove box lids), for their part, are produced by a conventional method of injecting a thermoplastic resin made of polypropylene ( PP) or ethylene / propylene (P / E) copolymer in a chemically grained steel mold.
Malheureusement, le résultat obtenu en terme de précision de moulage (grainage plus grossier) et de contrôle de jeux (rayons importants) s'avère nettement inférieur à ceux offerts par les procédés de « slush-molding » ou de PU spray, ce qui donne un aspect hétérogène à la planche de bord ou à l'habillage de portière et impacte négativement le niveau de qualité perçue par les usagers.  Unfortunately, the result obtained in terms of molding precision (coarser graining) and game control (large radii) is significantly lower than those offered by the "slush-molding" or PU spray processes, which gives a heterogeneous aspect to the dashboard or door trim and negatively impacts the level of quality perceived by users.
La demande de brevet DE 102006024263 Al décrit un procédé de fabrication d'un corps moulé multicouches dans lequel une feuille composée d'un film en élastomère thermoplastique appliqué sur un textile est positionné contre la matrice d'un moule présentant un motif décoratif grainé en négatif. DE 102006024263 A1 discloses a method of manufacturing a multilayer molded body in which a sheet made of a thermoplastic elastomer film applied to a textile is positioned against the matrix of a mold having a decorative pattern grained in negative.
La cavité de moulage du moule est ensuite refermée puis un polymère plastique est injecté dans cette cavité de sorte que le film thermoplastique soit comprimé contre la matrice grainée et se déforme du fait de la chaleur transmise par le matériau injecté en adoptant le motif décoratif.  The molding cavity of the mold is then closed and a plastic polymer is injected into this cavity so that the thermoplastic film is compressed against the grained matrix and deforms due to the heat transmitted by the injected material by adopting the decorative pattern.
Bien que le résultat obtenu en termes de précision de moulage et de contrôle de jeux soit meilleur qu'avec un procédé classique d'injection mono-matière, ce dernier s'avère encore nettement inférieur à ceux offerts par les procédés de « slush-molding » ou de PU spray.  Although the result obtained in terms of molding precision and game control is better than with a conventional mono-material injection method, the latter is still significantly inferior to those offered by the "slush-molding" processes. Or PU spray.
Objet et résumé de l'invention Object and summary of the invention
L'invention vise donc à améliorer le niveau de qualité perçue des éléments d'accastillage en plastique destinés à être rapportés par exemple sur les planches de bord ou les panneaux de porte d'un véhicule automobile.  The invention therefore aims to improve the level of perceived quality of plastic fittings to be reported for example on dashboards or door panels of a motor vehicle.
Elle propose à cet effet, un procédé de fabrication d'une pièce plastique moulée à surface externe grainée, caractérisé en ce qu'il comporte successivement les étapes suivantes :  It proposes for this purpose, a method of manufacturing a molded plastic part with external surface grained, characterized in that it comprises successively the following steps:
- injection d'un premier polymère thermoplastique dans une cavité de moulage délimitée par un poinçon et une première matrice de sorte à constituer un support rigide ;  injecting a first thermoplastic polymer into a molding cavity delimited by a punch and a first matrix so as to constitute a rigid support;
- retrait de ladite première matrice et remplacement de cette dernière par une seconde matrice présentant un motif décoratif grainé en négatif par incision laser directe et délimitant avec ledit poinçon et ledit support rigide une cavité de surmoulage ;  removing said first matrix and replacing the latter by a second matrix having a negative grained decorative pattern by direct laser incision and delimiting with said punch and said rigid support an overmolding cavity;
- injection d'un second polymère dans ladite cavité de surmoulage de sorte à constituer une peau de revêtement surmoulée contre ledit support et présentant une surface externe grainée reproduisant ledit motif ; et  injecting a second polymer into said overmolding cavity so as to constitute a skin of coating overmolded against said support and having a grained outer surface reproducing said pattern; and
- retrait de la deuxième matrice et éjection de ladite pièce moulée. Le procédé selon l'invention permet de réaliser pour un investissement et un coût de revient particulièrement raisonnables des éléments d'habillage intérieur pour véhicule automobile et notamment d'accastillage pour panneau porteur de planche de bord ou d'habillage intérieur de portière dont la peau de revêtement présente une qualité de grainage identique ou du moins très similaire à celle de la peau de revêtement d'un tel panneau porteur obtenu par un procédé nettement plus onéreux tel que le « slush-molding » ou le PU spray. - Removal of the second matrix and ejection of said molded part. The method according to the invention makes it possible to achieve, for a particularly reasonable investment and cost price, interior trim elements for a motor vehicle, and in particular for fittings for a dashboard carrying panel or interior door trim whose skin coating has a graining quality identical or at least very similar to that of the coating skin of such a carrier panel obtained by a much more expensive process such as "slush-molding" or PU spray.
Cette qualité de grainage permet ainsi d'obtenir une homogénéité visuelle d'aspect sur l'ensemble de la planche de bord ou de l'habillage intérieur de portière.  This graining quality thus makes it possible to obtain a visual homogeneity of appearance on the entire dashboard or interior door trim.
En outre, ce procédé peut être mis en œuvre dans la plupart des usines d'injection thermoplastique du monde, ce qui permet de produire les pièces localement et donc de réduire de manière conséquente les frais d'acheminement.  In addition, this process can be implemented in most thermoplastic injection plants in the world, which makes it possible to produce the parts locally and therefore significantly reduce the cost of delivery.
Selon des caractéristiques préférées du procédé selon l'invention, prises seules ou en combinaison :  According to preferred features of the process according to the invention, taken alone or in combination:
- ledit premier polymère thermoplastique injecté dans ladite cavité de moulage pour constituer ledit support rigide est choisi parmi le polypropylène (PP), le copolymère éthylène/propylène (P/E), l'acrylonitrile butadiène styrène (ABS), ou un mélange entre de l'acrylonitrile butadiène styrène et du polycarbonate (ABS/PC) ;  said first thermoplastic polymer injected into said molding cavity to constitute said rigid support is chosen from polypropylene (PP), ethylene / propylene copolymer (P / E), acrylonitrile butadiene styrene (ABS), or a mixture of acrylonitrile butadiene styrene and polycarbonate (ABS / PC);
- ledit premier polymère thermoplastique est renforcé en charges naturelles ou synthétiques ;  said first thermoplastic polymer is reinforced in natural or synthetic fillers;
- lesdites première et seconde matrices sont réalisées dans un même bloc métallique monté pivotant à 180° ;  said first and second dies are made in the same metal block pivoted at 180 °;
- ledit second polymère injecté dans ladite cavité de surmoulage pour constituer ladite peau de revêtement grainée est un élastomère thermoplastique (TPE) tel que par exemple un copolyester thermoplastique (TPE-E), un oléfine thermoplastique (TPE-O), un polyuréthanne thermoplastique (TPE-U) ou encore un copolymère à blocs styrèniques (TPE-S) ;  said second polymer injected into said overmoulding cavity to constitute said grained coating skin is a thermoplastic elastomer (TPE) such as, for example, a thermoplastic copolyester (TPE-E), a thermoplastic olefin (TPE-O), a thermoplastic polyurethane ( TPE-U) or a styrene block copolymer (TPE-S);
- ladite étape d'injection d'un second polymère est effectuée selon une technique de moulage par injection à réaction ; - ledit second polymère injecté dans ladite cavité de surmoulage pour constituer ladite peau de revêtement grainée est le polyuréthanne (PU) ; et/ou said step of injecting a second polymer is carried out according to a reaction injection molding technique; said second polymer injected into said overmoulding cavity to constitute said grained coating skin is polyurethane (PU); and or
- ladite première matrice délimitant partiellement ladite cavité de moulage est grainée chimiquement ou par électroérosion de sorte à améliorer la tenue mécanique de ladite peau de revêtement grainée sur ledit support ;  said first matrix partially delimiting said molding cavity is chemically grained or electro-erosion so as to improve the mechanical strength of said grained coating skin on said support;
L'invention vise également sous un second aspect un élément d'accastillage pour panneau porteur de planche de bord ou d'habillage intérieur de portière obtenu par un tel procédé.  The invention also aims, in a second aspect, with a deck hardware component for a dashboard or interior door trim panel obtained by such a method.
Selon des caractéristiques préférées dudit élément d'accastillage, ledit support présente une épaisseur comprise entre 1 et 5 mm, tandis que celle de ladite peau de revêtement est comprise entre 0,5 et 3 mm. Brève description des dessins  According to preferred features of said deck hardware, said support has a thickness of between 1 and 5 mm, while that of said skin of coating is between 0.5 and 3 mm. Brief description of the drawings
L'exposé de l'invention sera maintenant poursuivi par la description détaillée d'un exemple de réalisation, donnée ci-après à titre illustratif mais non limitatif, en référence aux dessins annexés, sur lesquels :  The description of the invention will now be continued by the detailed description of an exemplary embodiment, given below by way of illustration but without limitation, with reference to the appended drawings, in which:
- la figure 1 représente un organigramme du procédé selon l'invention de fabrication d'un corps moulé multicouches à surface externe texturée ;  - Figure 1 shows a flow chart of the method according to the invention for manufacturing a multilayer molded body with textured outer surface;
- les figures 2A à 2C illustrent les différentes étapes de mise en œuvre du procédé selon l'invention ; et  FIGS. 2A to 2C illustrate the different stages of implementation of the method according to the invention; and
- la figure 3 représente une vue en coupe d'une pièce moulée obtenue par le procédé selon l'invention.  - Figure 3 shows a sectional view of a molded part obtained by the method according to the invention.
Description détaillée d'un mode de réalisation Detailed description of an embodiment
Le procédé selon l'invention dont l'organigramme est représenté sur la figure 1 vise en particulier à permettre la réalisation d'un élément d'accastillage en plastique (tel que par exemple un enjoliveur ou un couvercle de boîte à gants) destiné à être rapporté sur un panneau porteur de planche de bord ou d'habillage intérieur de portière d'un véhicule automobile. La figure 2A illustre une première étape 100 de ce procédé au cours de laquelle un premier polymère thermoplastique est injecté à chaud et sous pression via une presse à injecter non représentée dans une cavité de moulage CM délimitée par un poinçon P et une première matrice en acier Mi, de sorte à constituer un support rigide S. The method according to the invention, the flowchart of which is shown in FIG. 1, is intended in particular to allow the production of a plastic fitting element (such as, for example, a hubcap or a glovebox cover) intended to be mounted on a panel of a dashboard or interior door trim of a motor vehicle. FIG. 2A illustrates a first step 100 of this method during which a first thermoplastic polymer is injected under pressure and under hot conditions via an injection molding machine not shown in a molding cavity CM delimited by a punch P and a first steel matrix Mi, so as to constitute a rigid support S.
Une telle presse à injecter comporte de manière classique, une trémie de collecte de granulés de résine thermoplastique et une vis sans fin motorisée et chauffée par l'intermédiaire de laquelle les granulés provenant de la trémie sont acheminés sous la forme d'un fluide visqueux injectable vers une tête d'injection reliée fluidiquement à au moins une buse BM ménagée dans le poinçon P et débouchant dans la cavité de moulage CM. Such an injection molding machine conventionally comprises a hopper for collecting thermoplastic resin granules and a heated motorized auger via which the granules coming from the hopper are conveyed in the form of an injectable viscous fluid. to an injection head fluidically connected to at least one nozzle B M formed in the punch P and opening into the mold cavity CM.
Le premier polymère thermoplastique constituant le support rigide est choisi de préférence parmi le polypropylène (PP), le copolymère éthylène/propylène (P/E), l'acrylonitrile butadiène styrène (ABS), ou un mélange entre l'acrylonitrile butadiène styrène et le polycarbonate (ABS/PC).  The first thermoplastic polymer constituting the rigid support is preferably chosen from polypropylene (PP), ethylene / propylene copolymer (P / E), acrylonitrile butadiene styrene (ABS), or a mixture of acrylonitrile butadiene styrene and polycarbonate (ABS / PC).
Afin d'améliorer la tenue mécanique de ce support, ce premier polymère thermoplastique est avantageusement renforcé en charges naturelles ou synthétiques (par exemples des charges minérales lamellaires telles que le talc ou des micro-fibrilles et nano-fibrilles minérales telle que les fibres de verre, etc.), par exemple à hauteur de 10 à 35% en poids.  In order to improve the mechanical strength of this support, this first thermoplastic polymer is advantageously reinforced in natural or synthetic fillers (for example lamellar mineral fillers such as talc or micro-fibrils and nano-mineral fibrils such as glass fibers etc.), for example up to 10 to 35% by weight.
Après cette opération de moulage du support et un temps de refroidissement, la première matrice Mi montée coulissante selon la direction de fermeture du moule est retirée (figure 2B) et remplacée par une seconde matrice M2 se refermant sur le poinçon P de sorte à délimiter avec ce dernier et le support S une cavité de surmoulage CSM (étape 200). After this molding operation of the support and a cooling time, the first matrix Mi mounted sliding in the closing direction of the mold is removed (Figure 2B) and replaced by a second matrix M 2 closing on the punch P so as to delimit with the latter and the support S an overmolding cavity CSM (step 200).
La surface de cette seconde matrice M2 présente un motif décoratif D grainé en négatif par incision laser directe et imitant par exemple l'aspect de surface du cuir ou du carbone. The surface of this second matrix M 2 has a decorative pattern D grained negative by direct laser incision and imitating, for example, the surface appearance of the leather or carbon.
Cette technique de grainage par un faisceau laser érodant directement la surface de la matrice M2 et dont le trajet est géré par une machine cinq axes commandée numériquement, permet de produire des textures complexes avec une très grande finesse de détails et de manière reproductible. This technique of graining by a laser beam directly eroding the surface of the matrix M 2 and whose path is managed by a numerically controlled five-axis machine, allows to produce complex textures with a great fineness of detail and in a reproducible way.
De manière avantageuse, la première et la seconde matrice Mi, M2 sont creusées dans un même bloc d'acier monté pivotant à 180° de sorte à simplifier le mécanisme de déplacement de ces matrices (un unique bras associé à un vérin pouvant alors assurer la fermeture ou l'ouverture de ces deux matrices). Advantageously, the first and the second matrix Mi, M 2 are hollowed out of the same steel block pivoted 180 ° so as to simplify the mechanism for moving these matrices (a single arm associated with a jack can then ensure closing or opening of these two matrices).
Comme montré sur la figure 2C, un second polymère est ensuite injecté à chaud et sous pression dans la cavité de surmoulage CSM (étape 300) de sorte à constituer une peau de revêtement R surmoulée contre le support S et présentant une surface externe grainée reproduisant le motif décoratif D.  As shown in FIG. 2C, a second polymer is then injected under heat and under pressure into the overmolding cavity CSM (step 300) so as to constitute a skin of coating R overmolded against the support S and having a grained external surface reproducing the decorative pattern D.
Cette seconde étape d'injection est effectuée via une seconde presse à injecter dont la tête d'injection est reliée fluidiquement à au moins une buse BSM ménagée dans le poinçon P et débouchant dans la cavité de surmoulage CSM. This second injection step is performed via a second injection molding machine, the injection head of which is fluidly connected to at least one nozzle B S M formed in the punch P and opening into the overmoulding cavity CSM.
Le second polymère constituant la peau de revêtement grainée R est avantageusement un élastomère thermoplastique (TPE) tel que par exemple un copolyester thermoplastique (TPE-E), un oléfine thermoplastique (TPE-O), un polyuréthanne thermoplastique (TPE-U) ou encore un copolymère à blocs styrèniques (TPE-S) tel que le SEBS, cette famille de polymères présentant une bonne résistance à l'abrasion et pouvant être facilement teintée.  The second polymer constituting the grained coating skin R is advantageously a thermoplastic elastomer (TPE) such as for example a thermoplastic copolyester (TPE-E), a thermoplastic olefin (TPE-O), a thermoplastic polyurethane (TPE-U) or a styrene block copolymer (TPE-S) such as SEBS, this family of polymers having good resistance to abrasion and can be easily tinted.
Selon des variantes de réalisation, la seconde étape d'injection peut également être effectuée selon une technique de moulage par injection à réaction (plus connue sous le terme anglais « Reaction injection molding » ou « RIM »).  According to alternative embodiments, the second injection step may also be carried out using a reaction injection molding technique (better known by the term "reaction injection molding" or "RIM").
Cette technique connue consiste à injecter dans une cavité de moulage (en l'espèce la cavité de surmoulage) et via une tête de mixage et d'injection un mélange de deux composants liquides provenant de deux unités d'alimentation distinctes et éventuellement associés à des additifs (tels que par exemple, un agent tensioactif, un catalyseur et/ou un agent moussant). Lorsqu'ils entrent en contact juste avant l'injection dans la cavité, ces deux composants réagissent chimiquement de manière exothermique l'un avec l'autre pour former un polymère sous forme liquide ou mousseuse. This known technique consists in injecting into a molding cavity (in this case the overmoulding cavity) and via a mixing and injection head a mixture of two liquid components coming from two separate feed units and possibly associated with additives (such as, for example, a surfactant, a catalyst and / or a foaming agent). When in contact just prior to injection into the cavity, these two components chemically react exothermically with each other to form a polymer in liquid or foamed form.
Cette réaction chimique provoque également une augmentation importante de la pression à l'intérieur de la cavité qui pousse le polymère dans toutes les parties de la cavité du moule.  This chemical reaction also causes a significant increase in the pressure inside the cavity that pushes the polymer into all parts of the mold cavity.
Ainsi, en choisissant pour les deux composants du mélange le polyisocyanate et le polyol, la réaction chimique formera du polyuréthanne sous forme de mousse qui sera injecté dans la cavité de surmoulage CSM pour constituer la peau de revêtement grainée R.  Thus, by choosing for the two components of the mixture the polyisocyanate and the polyol, the chemical reaction will form polyurethane in the form of foam which will be injected into the overmoulding cavity CSM to form the grained skin coating R.
Après cette seconde étape d'injection et un temps de refroidissement, la seconde matrice M2 est retirée et la pièce est éjectée du moule (étape 400). After this second injection step and a cooling time, the second die M 2 is removed and the workpiece is ejected from the mold (step 400).
On peut constater sur la figure 3 représentant la pièce obtenue après éjection que la face externe de sa peau de revêtement R présente un grainage reproduisant le motif décoratif D grainé en négatif dans la seconde matrice M2. It can be seen in Figure 3 showing the piece obtained after ejection that the outer face of its skin R coating has a graining reproducing the decorative pattern D grained negative in the second matrix M 2 .
De préférence, le support S aura une épaisseur comprise entre 1 et 5 mm, tandis que celle de la peau de revêtement R sera comprise entre 0,5 et 3 mm.  Preferably, the support S will have a thickness of between 1 and 5 mm, while that of the skin of coating R will be between 0.5 and 3 mm.
Le tableau ci-dessous présente plusieurs exemples de couples de polymères pouvant être associés pour constituer une telle pièce moulée à surface externe grainée.  The table below shows several examples of pairs of polymers that can be combined to form such a molded external surface molded part.
Support : Peau de revêtement : Support: Coating skin:
PP TPE-0  PP TPE-0
P/E TPE-0  P / E TPE-0
P/E chargé en fibres de verre TPE-0  P / E loaded with TPE-0 fiberglass
ABS TPE-U  ABS TPE-U
ABS PU ABS PU
ABS/PC TPE-U ABS / PC TPE-U
ABS/PC PU Selon des variantes de réalisation et afin d'améliorer la tenue mécanique de la peau de revêtement grainée R sur le support S, la première matrice Mi délimitant partiellement la cavité de moulage CM est avantageusement grainée chimiquement ou par électroérosion ("Electric Discharge Machining" en anglais). ABS / PC PU According to alternative embodiments and in order to improve the mechanical strength of the grained coating skin R on the support S, the first matrix Mi partially delimiting the molding cavity CM is advantageously chemically grained or by electro-erosion ("Electric Discharge Machining" in English).
On rappelle enfin que la présente invention ne se limite pas aux formes de réalisation décrites et représentées, mais qu'elle englobe également toutes les variantes d'exécution à la portée de l'homme du métier.  It is finally recalled that the present invention is not limited to the embodiments described and shown, but it also encompasses all the embodiments within the scope of those skilled in the art.

Claims

REVENDICATIONS
1. Procédé de fabrication d'une pièce plastique moulée à surface externe grainée, caractérisé en ce qu'il comporte successivement les étapes suivantes : 1. A method of manufacturing a molded plastic part with external surface grained, characterized in that it comprises successively the following steps:
- injection d'un premier polymère thermoplastique dans une cavité de moulage (CM) délimitée par un poinçon (P) et une première matrice (Mi) de sorte à constituer un support rigide (S) (100) ;  injecting a first thermoplastic polymer into a molding cavity (CM) delimited by a punch (P) and a first matrix (Mi) so as to constitute a rigid support (S) (100);
- retrait de ladite première matrice (Mi) et remplacement de cette dernière par une seconde matrice (M2) présentant un motif décoratif (D) grainé en négatif par incision laser directe et délimitant avec ledit poinçon (P) et ledit support rigide (S) une cavité de surmoulage (CSM) (200) ; - removal of said first matrix (Mi) and replacement of the latter by a second matrix (M 2 ) having a decorative pattern (D) grained negative by direct laser incision and delimiting with said punch (P) and said rigid support (S ) an overmolding cavity (CSM) (200);
- injection d'un second polymère dans ladite cavité de surmoulage (CSM) de sorte à constituer une peau de revêtement (R) surmoulée contre ledit support (S) et présentant une surface externe grainée reproduisant ledit motif (D) (300) ; et  injecting a second polymer into said overmoulding cavity (CSM) so as to constitute a coating skin (R) overmolded against said support (S) and having a grained outer surface reproducing said pattern (D) (300); and
- retrait de la deuxième matrice et éjection de ladite pièce moulée (400).  - Removal of the second matrix and ejection of said molded part (400).
2. Procédé selon la revendication 1, caractérisé en ce que ledit premier polymère thermoplastique injecté dans ladite cavité de moulage (CM) pour constituer ledit support rigide (S) est choisi parmi le polypropylène (PP), le copolymère éthylène/propylène (P/E), l'acrylonitrile butadiène styrène (ABS), ou un mélange entre de l'acrylonitrile butadiène styrène et du polycarbonate (ABS/PC).  2. Method according to claim 1, characterized in that said first thermoplastic polymer injected into said molding cavity (CM) to form said rigid support (S) is chosen from polypropylene (PP), ethylene / propylene copolymer (P / E), acrylonitrile butadiene styrene (ABS), or a mixture of acrylonitrile butadiene styrene and polycarbonate (ABS / PC).
3. Procédé selon l'une des revendications 1 ou 2, caractérisé en ce que ledit premier polymère thermoplastique est renforcé en charges naturelles ou synthétiques.  3. Method according to one of claims 1 or 2, characterized in that said first thermoplastic polymer is reinforced in natural or synthetic fillers.
4. Procédé selon l'une des revendications 1 à 3, caractérisé en ce que lesdites première et seconde matrices (Mi, M2) sont réalisées dans un même bloc métallique monté pivotant à 180°. 4. Method according to one of claims 1 to 3, characterized in that said first and second matrices (Mi, M 2 ) are made in the same metal block rotatably mounted at 180 °.
5. Procédé selon l'une des revendications 1 à 4, caractérisé en ce que ledit second polymère injecté dans ladite cavité de surmoulage (CSM) pour constituer ladite peau de revêtement grainée (R) est un élastomère thermoplastique (TPE) tel que par exemple un copolyester thermoplastique (TPE-E), un oléfine thermoplastique (TPE-O), un polyuréthanne thermoplastique (TPE-U) ou encore un copolymère à blocs styrèniques (TPE-S). 5. Method according to one of claims 1 to 4, characterized in that said second polymer injected into said overmoulding cavity (CSM) to form said grained coating skin (R) is a thermoplastic elastomer (TPE) such as for example a thermoplastic copolyester (TPE-E), a thermoplastic olefin (TPE-O), a thermoplastic polyurethane (TPE-U) or a styrene block copolymer (TPE-S).
6. Procédé selon l'une des revendications 1 à 4, caractérisé en ce que ladite étape d'injection d'un second polymère (300) est effectuée selon une technique de moulage par injection à réaction.  6. Method according to one of claims 1 to 4, characterized in that said step of injecting a second polymer (300) is performed according to a reaction injection molding technique.
7. Procédé selon la revendication 6, caractérisé en ce que ledit second polymère injecté dans ladite cavité de surmoulage (CSM) pour constituer ladite peau de revêtement grainée (R) est le polyuréthanne (PU).  7. Method according to claim 6, characterized in that said second polymer injected into said overmoulding cavity (CSM) to form said grained coating skin (R) is polyurethane (PU).
8. Procédé selon l'une des revendications 1 à 7, caractérisé en ce que ladite première matrice (Mi) délimitant partiellement ladite cavité de moulage (CM) est grainée chimiquement ou par électroérosion de sorte à améliorer la tenue mécanique de ladite peau de revêtement grainée (R) sur ledit support (S).  8. Method according to one of claims 1 to 7, characterized in that said first matrix (Mi) partially delimiting said molding cavity (CM) is chemically grained or electro-erosion so as to improve the mechanical strength of said skin coating grained (R) on said support (S).
9. Elément d'accastillage pour panneau porteur de planche de bord ou d'habillage intérieur de portière caractérisé en ce qu'il est obtenu par un procédé selon l'une des revendications 1 à 8.  9. Fitting element for dashboard door panel or interior door trim characterized in that it is obtained by a method according to one of claims 1 to 8.
10. Elément d'accastillage selon la revendication 9, caractérisée en que ledit support (S) présente une épaisseur comprise entre 1 et 5 mm, tandis que celle de ladite peau de revêtement (R) est comprise entre 0,5 et 3 mm.  10. Hardware element according to claim 9, characterized in that said support (S) has a thickness of between 1 and 5 mm, while that of said skin of coating (R) is between 0.5 and 3 mm.
EP18801021.9A 2017-11-08 2018-10-26 Method for producing a moulded plastic part with a grained outer surface of higher quality Pending EP3706973A1 (en)

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FR1760501A FR3073169A1 (en) 2017-11-08 2017-11-08 PROCESS FOR MANUFACTURING A MOLDED PLASTIC PIECE WITH EXTERIOR GRAIN SURFACE OF HIGHER QUALITY.
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WO2019092342A1 (en) 2017-11-08 2019-05-16 Psa Automobiles Sa Method for producing a moulded plastic part with a grained outer surface of higher quality

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US4422995A (en) * 1981-12-07 1983-12-27 Husky Injection Molding Systems Ltd. Method and apparatus for molding hollow, slender workpieces
DE102006024263A1 (en) 2006-05-24 2007-11-29 Ise Intex Gmbh Plastic moldings made by back-injection for use as interior lining parts for cars, comprise a thin thermoplastic film with an impressed pattern on the surface, an open-structured backing and a rigid plastic support
DE102010031814A1 (en) 2010-07-21 2011-05-12 Daimler Ag Method for manufacturing mold tool for forming mold part for e.g. body part in automotive industry, involves producing positive structure on mold part surface of mold part formed with mold tool
FR3073169A1 (en) 2017-11-08 2019-05-10 Psa Automobiles Sa PROCESS FOR MANUFACTURING A MOLDED PLASTIC PIECE WITH EXTERIOR GRAIN SURFACE OF HIGHER QUALITY.

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2019092342A1 (en) 2017-11-08 2019-05-16 Psa Automobiles Sa Method for producing a moulded plastic part with a grained outer surface of higher quality

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