EP4334104A1

EP4334104A1 - Method for manufacturing a coated plastic part

Info

Publication number: EP4334104A1
Application number: EP22724817.6A
Authority: EP
Inventors: Christophe Cazes; François LELIEVRE; Miguel FRADE
Original assignee: Novares France SAS
Current assignee: Novares France SAS
Priority date: 2021-05-06
Filing date: 2022-05-04
Publication date: 2024-03-13
Also published as: FR3122602B1; FR3122602A1; WO2022234231A1

Abstract

The invention relates to a method for manufacturing a coated plastic part (1) intended to be integrated into a passenger compartment of a motor vehicle, the coated plastic part including a base part comprising a raised section (6), and a sheet (3) comprising a useful surface (11), the method comprising a step of creating (102, 201) at least one flap (12) in the useful surface, a positioning step (103, 202) in which the sheet is positioned opposite a shaping tool (15) comprising a raised area (14) of a complementary shape to the raised section (6), a shaping step (104, 203), in which the sheet is pressed against the shaping tool (15), and a joining step (105, 204) in which the sheet and the base part are held against each other so as to facilitate the rigid connection of the sheet and the base part.

Description

Process for manufacturing a coated plastic part

The present invention relates to a thermoplastic passenger compartment part for a motor vehicle, in particular a coated plastic part, decorated and/or having a control device and a process for manufacturing the coated plastic part.

The passenger compartment of a motor vehicle constitutes for users - driver and possible passengers - a place of life and interaction, and includes coated plastic parts.

Coated plastic parts refer to any part made of a thermoplastic material and covered with a sheet. The sheet can be an active sheet, that is to say a sheet fitted with electrical or electronic components, for example sensors, or an inert sheet, that is to say a sheet devoid of any electrical or electronic component.

Coated plastic parts comprising an active sheet are generally used within control devices, making it possible to control vehicle functions.

These functions are very diverse in nature and may relate in particular to the opening and closing of the vehicle doors, the orientation of the side mirrors, as well as the opening and closing of the windows fitted to the side doors of the vehicle. The commands which are typically found inside a vehicle and which constitute the interface for controlling the functions of a vehicle are in particular of the type: push buttons for, for example, controlling the locking of a vehicle, rotary knobs to, for example, control the temperature setting of the air conditioning system; rocker buttons, for example, to control the window opening/closing mechanism trigger, for example, to control the door opening mechanism sliders, for example, to control the temperature setting of the air conditioning system

Control devices comprising such coated plastic parts are located in several places within the passenger compartment, for example on the door trim, in the armrest, near the gear lever, or even on the steering wheel. The vehicle interior is thus equipped with a multitude of control devices.

More precisely, in a control device with electrical controls, each of the control zones is assigned to a specific function of the motor vehicle. The control device thus produced comprises a coated plastic part integrating an active sheet, sensitive to proximity and/or to touch via a surface of detection coated with sensors. The sheet is arranged on the surface of a plastic part, called the base part, in such a way that each of the sensors are contiguous, that is to say, faces one of the control zones.

Each sensor is configured for example to detect the proximity and/or the touch of a user's finger, by sending a signal to an electronic control unit arranged on a printed circuit board.

The contiguity between the sensors and the control zones is essential to allow the achievement of a good detection of the finger of the user, and thus to guarantee a good reactivity of the chosen function.

The control zones are arranged on a flat sector or a sector in relief. By sector in relief, reference is made to any zone having a clumsy shape, for example an embossment or a hollow.

Coated plastic parts comprising an inert sheet are often used on the dashboard, the armrests of the doors, the steering wheel or even on the central console. Such parts are provided with visual indications, most of the time painted, or printed on the inert sheet. Such visual indications are often decorative or informative. It is important that the visual rendering after manufacture of the coated plastic part be as precise as possible, i.e. correspond to that desired in the design phase, in particular during application on raised sectors of the basic piece.

Also, in general, it is sought that the useful surfaces of the sheet, that is to say surfaces intended to receive a component in the case of an active sheet, or to receive a visual indication in the case of an inert sheet, can conform to raised areas.

Typically, to manufacture a coated plastic part, the sheet is thermoformed on a surface of the base part, in order to allow the shapes of the base part to be matched. Such a method of assembling the sheet on the base part consists in heating the sheet to a predetermined temperature, before applying it by pressure to a surface of the base part.

An example of manufacturing by thermoforming of a control device integrating a coated plastic part is described in WO 201358708 (FISCHER TECHNOLOGY).

The thermoforming process allows the attachment of the sheet to the shape of the base part. However, it has been observed that following the application of the sheet to the base part, a lack of contiguity, in other words a shift between the control zones having sectors in relief, and the surfaces may appear. Such an anomaly comes from excessive stretching of the sheet when applying it to the inner surface. Stretching generates a deformation which remains during the hardening of the sheet after cooling.

Another anomaly can be observed with the deformation of the pictograms, logos or decorative patterns of a passive sheet during this thermoforming step.

In the case of an active sheet, such a lack of contiguity has the consequence that the components in the useful zone, for example sensors undergo a deformation themselves, or else are moved and do not find themselves opposite the zones of ordered. If the components are sensors, the contiguity defect has the consequence that the detection of the contact is deficient, because the measured physical value no longer corresponds to the physical value as initially envisaged. It is therefore necessary before any commissioning of the control device comprising the coated plastic part to recalibrate the sensor. However, such a recalibration impacts the manufacturing time as well as the overall production cost of the control device.

Moreover, such a thermoforming operation can damage the electronic components themselves because the hot deformation of the active sheet having these components can be significant in certain places, in particular when the plastic part comprises sectors in relief with complex shapes. or with small radii of curvature. Likewise, the heat required for this thermoforming operation can damage the components, in particular the sensors. Also, a significant number of rejects of coated plastic parts manufactured using such a process has been observed.

Also, such a process for manufacturing the coated plastic part is energetically costly, in particular due to the use of a heat source to allow the thermoforming to be performed, and also requires additional manufacturing cycle time.

Such drawbacks are also found for the manufacture of a coated plastic part comprising an inert sheet.

The invention aims in particular to solve the aforementioned drawbacks.

A first objective is to propose a method for manufacturing a coated plastic part, which allows, in the case of a sheet equipped with sensors, to achieve good detection in a control device integrating such a coated plastic part.

A second objective is to propose such a method which makes it possible to produce a coated plastic part having sectors in relief of complex shape.

A third objective is to propose such a process, which offers limited energy consumption, and a reduced manufacturing cycle time.

A fourth objective is to provide a coated plastic part obtained by such a process. A fifth objective is to provide a motor vehicle comprising such a coated plastic part.

To this end, there is firstly proposed a method for manufacturing a coated plastic part intended to be integrated into a passenger compartment of a motor vehicle, the coated plastic part including a base part made of thermoplastic material comprising at least one sector in relief, a sheet comprising at least one useful surface, the method comprising a step of creating at least one flap in the useful surface, a positioning step in which the sheet is positioned facing a shaping tool comprising a area in relief with a shape complementary to the sector in relief of the base part, the useful surface being positioned opposite the area in relief, a shaping step in which the sheet is pressed against the shaping tool, the flap being moved to come into contact with the area in relief, a bonding step in which the sheet and the base part are held against each other so as to allow the joining together tion of the sheet and the base piece.

The production of flaps which are applied to sectors in relief makes it possible to avoid the creation of a gap between the sheet and the surface of the base part during the application of the sheet, and to dispense with thermoforming when joining the sheet to the base part. In addition, the method is reliable and easily carried out on known machines.

Advantageously, during the shaping step, the sheet is pressed against the shaping tool by means of a suction force created by a depression coming from the shaping tool.

Advantageously, the method comprises a creation step comprising making cutouts and markings of at least one fold within the useful surface, according to a predetermined pattern, so as to define a flap.

Advantageously, the cutouts are made using a punch tool, a cutting blade, a plasma cutting tool, or a laser cutting tool.

Advantageously, the marking of at least one fold is carried out using a laser or stamping tool.

Advantageously, the base part is obtained before the bonding step, the method comprising, before the positioning step, a gluing step including the application of an adhesive to the useful surface, the joining between the sheet and the Base piece when bonding step is performed by curing the applied adhesive.

Advantageously, the adhesive is a glue deposited on the useful surface by spraying, or by rolling or by applying a stencil previously glued with the glue.

Advantageously, the linking step is carried out within a die-stamping machine, the die-stamping machine comprising a die capable of translating, the die being provided with the shaping tool, the die-stamping machine also comprising a base receiving the base part, during the bonding step the die translates and comes into contact with the base part and the sheet.

Advantageously, the method comprises an injection step, the injection step and the joining step being carried out in an injection molding machine comprising a first half-mold having a molding wall provided with the setting tool shaped provided with a suction force allowing the sheet to be applied against the shaping tool, the half-molds moving relative to each other and being able to be joined in a sealed manner between them by defining a molding cavity having a shape identical to the base part, during the injection step, the half-molds are joined together, liquid thermoplastic is introduced into the cavity, the joining step being operated by cooling the thermoplastic injected into the molding cavity.

Secondly, there is proposed a coated plastic part intended to be integrated within a passenger compartment, the plastic part comprising a base part, and a sheet, the base part and the sheet being integral with one of the other, the plastic part being obtained according to the process presented above.

Advantageously, the sheet of the coated plastic part is an active sheet comprising at least one useful surface provided with a sensor.

Thirdly, a motor vehicle provided with said coated plastic part is proposed.

Other characteristics and advantages of the invention will appear more clearly and concretely on reading the following description of embodiments, which is made with reference to the appended drawings in which:

[Fig. 1] shows a schematic top view of a sheet with cutouts;

[Fig. 2] shows a schematic top view of a sheet having glued useful surfaces;

[Fig. 3] shows a schematic top view of a sheet after shaping;

[Fig. 4] represents a schematic perspective view of a basic part;

[Fig. 5] represents a flowchart illustrating the different steps of a process for manufacturing a coated plastic part according to the first method of manufacture;

[Fig. 6] shows a schematic sectional view of a stamping machine for manufacturing according to the first method of manufacturing the coated plastic part, the stamping machine being shown in a positioning step; [Fig. 7] shows a schematic sectional view of a stamping machine for manufacturing according to the first method of manufacturing the coated plastic part, the stamping machine being shown in a shaping step;

[Fig. 8] shows a schematic sectional view of a stamping machine for manufacturing according to the first method of manufacturing the coated plastic part, the stamping machine being shown in a removal step;

[Fig. 9] shows a schematic sectional view of a stamping machine for manufacturing according to the first method of manufacturing the coated plastic part, the stamping machine being shown in a joining step;

[Fig. 10] shows a flowchart of a manufacturing process according to the second method of manufacturing the coated plastic part;

[Fig. 11] shows a schematic sectional view of an injection molding machine for manufacturing a coated plastic part obtained according to the second manufacturing method, the injection molding machine being shown in a positioning step;

[Fig. 12] shows a schematic sectional view of an injection molding machine for manufacturing a coated plastic part obtained according to the second manufacturing method, the injection molding machine being shown in a shaping step;

[Fig. 13] shows a schematic cross-sectional view of an injection molding machine for manufacturing a coated plastic part obtained according to the second manufacturing method, the injection molding machine being shown in a joining step;

[Fig. 14] shows a schematic sectional view of an injection molding machine for manufacturing a coated plastic part obtained according to the second manufacturing method, the injection molding machine being shown in a release step;

Figure 1 shows a coated plastic part 1, that is to say a base part 2 provided with a sheet 3. The sheet 3 covers a connecting surface 4 of the base part 2.

The coated plastic part 1 is intended to be integrated within the passenger compartment of a vehicle, for example a motor vehicle (not shown).

The coated plastic part 1 illustrated in FIG. 1 is intended to be implemented, for example, within a door of a motor vehicle (not shown). The coated plastic part 1 thus represented is for example intended to be integrated into a door control device performing functions such as the opening and closing of doors. side windows, the locking and unlocking of the doors, as well as the orientation of the side mirrors.

In other embodiments not shown, the coated plastic part 1 is intended to be integrated into the dashboard of a vehicle, or within a central console module. The coated plastic part 1 is for example intended to be integrated within a dashboard control device comprising, for example, controls for the vehicle engine start functions, or for cabin ventilation.

Typically, a control device makes it possible to create an interface between the user and a control unit, for example an on-board computer of the vehicle (not shown).

In other embodiments, the coated plastic part 1 is integrated into other interior parts of the vehicle, for example a gear lever, a directional steering wheel, a control box close to a steering wheel such as a commodo , or an armrest of a seat.

The coated plastic part 1 comprises a sheet 3 arranged on a base part 2.

In the embodiments shown, the basic part 2 offers a general structure of a solid part, but in other embodiments not shown, the part

2 base comes in the form of a shell. Such an arrangement allows the basic part 2 to be easily inserted into the trim of a door, a dashboard, or any other element of the passenger compartment designed to receive the coated plastic part 1.

The base part 2 is preferably made of a thermoplastic material, and is advantageously obtained by a molding process, for example by injection molding, as described below.

The connecting surface 4 of the base part 2 is intended to be covered by the sheet 3.

As can be seen in particular for example in Figure 1, the base part 2 comprises flat sectors 5 and sectors 6 in relief. The sectors 6 in relief comprise embossments 7 protruding from the connecting surface 4, or recesses 8 in the connecting surface 4. In order to allow manufacture of the coated plastic part 1 according to the methods described later in the description, the embossments 7 and the hollows 8 are provided with a shallow depth, this limited depth can be determined by experience.

We now describe more particularly the sheet 3, with reference to Figures 2,

3 and 4.

Sheet 3 is advantageously made of a thermoplastic material, for example a polymer substrate, such as that used for flexible printed circuits, or polyethylene terephthalate (PET) coated with indium-tin oxide (ITO). In order to facilitate its assembly on the connecting surface 4 of the base part 2, the sheet 3 is made with such flexibility that it can for example be rolled up manually.

In one embodiment, sheet 3 is active, that is to say provided with electrical or electronic devices (not shown). For example, the sheet 3 comprises an active face advantageously coated with a substrate (not visible in the figures) allowing the printing of tracks (not shown) and sensors (not shown). The tracks are for example connected to sensors, as well as to the printed circuit board.

In another embodiment, the sheet 3 is passive, that is to say devoid of electrical or electronic devices, but preferably comprises only a visual coating such as paint, for example to represent a pattern, a logo , a pictogram or any other decorative means.

Whether the sheet 3 is active or passive, it advantageously comprises a free, visible face 9 and a contact face 10, intended to be secured to the base part 2.

Advantageously, the contact face 10 comprises a useful surface 11 . In the case of an active sheet 3, the useful surface 11 is intended to accommodate an electrical or electronic device linked to a command, and is intended to receive the user's finger.

In embodiments not shown, the sheet 3, whether active or inert, receives visual indications taking the form, for example, of painted or printed pigments.

A useful surface 11 is integrated for example in a flap 12, advantageously obtained by cutting, as described later in the description.

As can be seen in Figure 3, the sheet 3 comprises a plurality of useful surfaces 11. Such useful surfaces 11 are positioned sufficiently far from each other so that flaps 12 can be formed, and be moved according to the manufacturing methods 100, 200 described below.

A first example of a manufacturing method 100 of the control device 1 will now be described with reference to FIGS. 5 to 9.

In a gluing step 101, the useful surface 11 of the sheet 3 is coated with a glue or an adhesive, so as to allow the assembly of the sheet 3 on the connecting surface 4 of the part 2 of base. The use of glue makes it possible to carry out an assembly, a joining, a connection of the sheet 3 on the coated plastic part 1 while avoiding any thermoforming. In this way, the risk of undesirable deformation of the sheet 3 is limited, and energy consumption is controlled.

Advantageously, during the gluing step 101 , the glue is deposited by spraying, or rolling or by applying a previously glued stencil. In a creation step 102, cutouts 13 are advantageously made within the useful surface 11, according to a predetermined pattern, so as to form the flap 12. The pattern of the cutouts 13 is determined according to the sector 6 in relief to be put on. The cutouts 13 are advantageously in the form of a broken line, for example with three sides.

During the creation step 102, a fold 23 is made. Such a fold 23 advantageously connects the flap 12 to the useful surface 11. In this way, the fold 23 acts as a hinge which allows the flap 12 to move according to the sector 6 in relief to be coated. In this way, the flap 12 comprising several cutouts and at least one fold 23 is able to marry a complementary shape of the basic part 2 such as the sector 6 in corresponding relief.

Advantageously, the fold 23 is marked using a stamping tool or a laser tool.

The flaps 12 also have the role that the useful surface 11 is well opposite the sector 6 in corresponding relief. This makes it possible to ensure that the sheet 3 is deposited with precision on the surface 4 of connection.

In the case of an active sheet 3, a precise deposition of the sheet 3 on the connecting surface 4 prevents the application of an effort by the user from being detected erroneously.

Also, the application of a finger of the user on a sensor arranged within the sheet 3 only activates the detection of said sensor associated with the associated control zone, and not another sensor. The occurrence of an undesirable deformation of any sensor unrelated to the function chosen by the user of a control device integrating the coated plastic part 1 is therefore considerably limited.

In the case of an inert sheet 3, the production of such flaps 12 has the advantage of making it possible to obtain a coating having a rendering as close as possible to that desired, without the risk of creases occurring, or defects in 'alignment.

Advantageously, the cutouts 13 are made with a punch tool, which allows rapid and economical formation of the flaps 12.

In other embodiments, the cutouts 13 are made with other means: a blade, by laser or plasma cutting. The choice of such means makes it possible to adapt the precision and the speed of production of the flaps according to the type of application desired for the coated plastic part 1.

In a positioning step 103, the sheet 3 is placed opposite a shaping tool 15 comprising a forming surface 16 . The forming surface 16 comprises a raised area 14, of complementary shape to the connecting surface 4, that is to say that the raised area 14 has the “negative” of the sector 6 in relief. The shaping tool 15 materializes for example in the form of a plate having the forming surface 16 . In this way, such a plate can for example be integrated on a die, a mould, a shell, a vice, which allows the manufacturing process to be carried out on several different types of machines.

In a shaping step 104, the sheet 3, more precisely the free face 9 is pressed against the shaping tool 15, and once pressed, is kept applied against the shaping tool 15. In other words, in such a step, the sheet 3 is gripped by the shaping tool 15. Such an operation is carried out for example by means of a suction force which generates a flow of depression air, or else by a dedicated mechanical device (not shown).

In advantageous embodiments, it is possible to combine the suction force with the use of a dedicated mechanical device, which makes it possible to increase the pressing force.

Advantageously, the shaping tool 15 comprises a plurality of nozzles 17 connected to a vacuum generating device. The nozzles 17 are advantageously arranged in a regular manner, in particular in a direction substantially normal to the forming surface 16 . The suction force is thus distributed all along the forming surface 16, which avoids causing an offset between the forming surface 16 and the sheet 3, or the formation of undesirable folds. Consequently, in the case of an active sheet equipped with sensors, it is possible to increase the quality of detection compared to known methods, or for a passive sheet to obtain an aesthetic rendering closest to that expected.

In order to guarantee alignment precision, and to ensure that each sector 6 in relief faces each of the areas 14 in relief, the shaping tool 15 comprises centering pins 18, able to come insert within positioning holes 19 provided in the sheet.

In a bonding step 105, the sheet 3 is brought closer to the base part 2 until the sheet 3 is secured to the bonding surface 4. For example, the sheet 3 is kept applied for the time that the bonding between the bonding surface 4 and the forming surface 16 takes.

The manufacturing process 100 according to the first manufacturing mode is advantageously carried out on a stamping machine 20 as shown in FIGS. 6 to 9.

Such a stamping machine 20 comprises for example a die 21, which translates in a vertical direction, and a base 22 fixed relative to the die 21. The base 22 receives a base part 2, the die 21 comprises a tool 15 of shaping. During the creation step 102, the sheet 3 is for example introduced into a cutting machine (not shown), so as to allow the production of the cutouts 13. Advantageously, the sheet 3 provided with cutouts 13 is positioned facing the shaping tool 15 arranged within the matrix 21, as shown in Figure 6.

During the shaping step 104, illustrated in FIG. 7, the die 21 remains immobile, the sheet 3 being for example moved by suction created by depression, so that the free face 9 is sucked up and brought into contact with the shaping tool 15.

More specifically, during the shaping step 104, the flaps 12 are moved and open thanks to the cutouts 13, forming a fold 23. Thus, the flaps 12 can come into contact with areas 14 in relief. As explained above in the description, such an arrangement makes it possible to obtain good contiguity between the sector 6 in relief and the area 14 in relief. In this way, the production quality of the coated plastic part 1 will be increased.

The bonding step 105 represented in FIG. 8 is advantageously carried out by translating the matrix 21 downwards, which makes it possible to place the contact face 10 against the bonding surface 4. In this way, the adhesive deposited on the contact face 10 engages with the bonding surface 4, for example by hardening, allowing the joining of the sheet 3 and the base part 2.

Advantageously, after securing the sheet 3 and the base part 2, during a withdrawal step 106, the matrix 21 is moved away from the base 22, by being for example translated upwards, as it can be observed in Figure 9, which makes it possible to extract the coated plastic part 1 from the stamping machine 20 .

Such a process 100 according to a first manufacturing mode does not require any heating, which makes it possible to limit energy consumption. Moreover, such a process can be carried out on known machines. Finally, the process 100 makes it possible to obtain a coated plastic part 1 comprising a sheet 3 whose sectors 6 in relief are well opposite the useful surfaces 11, which makes it possible to reduce the rate of non-compliance with respect to the processes known from the prior art.

A second method of manufacturing the coated plastic part 1 will now be described with reference to Figures 10 to 14.

The method 200 includes a step 201 for creating the flaps 12, and a step for positioning 202, these two steps being respectively identical to the step for creating 101 and the step 103 for positioning the first manufacturing method.

Unlike the first manufacturing mode, according to the second manufacturing mode, the basic part 2 is manufactured after a shaping step 203, whereas according to the first manufacturing method, the basic part 2 is manufactured prior to the manufacturing process 100.

More specifically, the method 200 includes an injection step 204 in which the basic part 2 is produced as explained below.

It can be seen in FIGS. 11 to 14 that the method 200 is advantageously carried out within an injection molding machine 24 comprising a mold 25 formed of a first half-mold 26, and of a second half-mold. mold 27. The first half-mold 26 comprises the shaping tool 15, arranged in such a way that it forms a molding wall 28 . Such a molding wall 28 comes into direct contact with the material introduced into the mold 25, so as to leave its imprint. In this way, it is possible to form a raised sector 6 and a flat sector 7 on the connecting surface 4.

As can be seen in Figure 13, the second half-mold 27 is for example connected to a thermoformable material injection molding machine (not shown), via an orifice 29 passing through a rear wall 30 of the mold through a channel 31.

In other embodiments not shown, the material injection molding machine is connected differently to the second half-mold 27.

The first half-mold 26 and the second half-mold 27 are movable between an open position and a closed position.

In the open position, visible in Figures 11 and 14, the half-molds 26, 27 are separate, separated from each other, allowing access to the interior of the half-molds 26, 27.

In the closed position, visible in Figures 12 and 13, the half-molds 26, 27 are joined, that is to say in contact with one another, in order to define a sealed molding cavity 32, which has a volume, an imprint, a shape identical to the basic part 2. In this way, it is possible to allow the molding of a basic part 2 having a connecting surface 4 provided with sectors 6 in relief.

In the method 200, during the positioning step 203, or during the shaping step 204, or after such steps, the half-molds 26, 27 are brought together, which has the consequence of form the sealed cavity 32.

Once the cavity 32 has been formed, molten thermoplastic material is injected under pressure through the orifice 29, in order to obtain the filling of the half-molds 26, 27, and allow the molten thermoplastic material to enter in contact with the surface 16 forming.

In order to avoid any melting or any undesirable deformation of the sheet 3 due to contact with the molten thermoplastic, such a thermoplastic is chosen by having a melting temperature lower than the melting temperature of the material constituting the sheet 3. The thermoplastic material is melted, for example, by heating thermoplastic pellets (not shown), such heating taking place outside the injection molding machine 24 .

During the injection step 204, the molten thermoplastic material comes into contact with the sheet 3, held against the shaping tool 15. Advantageously, during this injection step, the free face 9 is kept in contact with the forming surface 16.

During the bonding step 205, the base part 2 formed solidifies, for example by stopping the heating of the half-molds 26, 27. During the solidification, the thermoplastic material hardens, allowing the bonding of the sheet 3 with the base part 2, which has the result that the contact face 10 is molded onto the connecting surface 4 of the base part 2.

During a release step 206, the half-molds 26, 27 are placed in the open position, which makes it possible to eject the coated plastic part 1.

The manufacturing process according to such a second manufacturing method makes it possible to dispense with a gluing step. In addition, it allows within the same machine to form the basic part 2, and to set up the sheet 3 on the basic part 2. Also, the second mode of manufacture saves time on manufacture, and therefore improves the productivity of the production line.

Commonly to the first mode of manufacture, and to the second mode of manufacture, the method of manufacturing 100, 200 of the coated plastic part 1 offers many advantages, in particular: the possibility of positioning flaps 12 in sectors 6 in relief having complex shapes, reduced energy use compared to a process using thermoforming, possible implementation on pre-existing machines such as a stamping machine, or an injection molding machine, reduced manufacturing time.

Claims

1. Process (100, 200) for manufacturing a coated plastic part (1) intended to be integrated into a passenger compartment of a motor vehicle, the coated plastic part (1) including

- a base part (2) made of thermoplastic material comprising at least one sector (6) in relief,

- a sheet (3) comprising at least one useful surface (11), the method (100) comprising:

- a creation step (102, 201) of at least one flap (12) in the useful area,

- a positioning step (103, 202) in which the sheet (3) is positioned facing a shaping tool (15) comprising an area (14) in relief of a shape complementary to the sector (6) in relief, the useful surface (11) being positioned facing the area (14) in relief,

- a shaping step (104, 203), in which the sheet (3) is pressed against the shaping tool (15), the flap (12) being moved to come into contact with the domain (14) embossed,

- a connecting step (105, 204) in which the sheet (3) and the base part (2) are held against each other so as to allow the joining of the sheet (3) and the part (2) basic.

2. Method (100, 200) according to the preceding claim, characterized in that during the shaping step (104, 203), the sheet (3) is pressed against the tool (15) for shaping through a suction force created by a depression coming from the shaping tool (15).

3. Method (100, 200) according to claim 1 or 2, characterized in that it comprises a creation step (102, 201) comprising making cutouts (13) and marking at least one fold (23 ) within the useful surface (11), according to a predetermined pattern, so as to define at least one flap (12).

4. Method (100, 200) according to the preceding claim, characterized in that the cutouts (13) are made using a punch tool, a cutting blade, a plasma cutting tool, or a laser cutter.

5. Method (100) according to any one of the preceding claims, characterized in that the base part (2) is obtained before the step (103) of bonding, the method comprising before the step (103, 202) positioning, a gluing step (101) including the application of an adhesive on the useful surface (11), the joining between the sheet (3) and the base part (2) during the step (105 ) bonding is effected by curing the applied adhesive.

6. Method (100) according to the preceding claim, characterized in that the adhesive is an adhesive deposited on the surface (11) useful by spraying, or by rolling or by applying a stencil previously glued with the adhesive.

7. Method (100) according to any one of the preceding claims, characterized in that the linking step (105) is carried out within a die-stamping machine (20), the die-stamping machine (20) comprising a die (21) able to translate, the die (21) being equipped with the shaping tool (15), the die-stamping machine (20) also comprising a base (22) receiving the base part (2) , during step (105) of connecting the matrix translating towards the base (22) and bringing the base part (2) and the sheet (3) into contact.

8. Method (200) according to any one of claims 1 to 4, characterized in that it comprises a step (204) of injection, the step (204) of injection and the step (205) of connection being made in an injection molding machine (24) comprising a first half-mold (26) having a molding wall (28) provided with the shaping tool (15), the half-molds (26, 27) moving relative to each other and being able to be joined in a leaktight manner to one another by defining a molding cavity (32) having a shape identical to the base part (2), when injection step (204), the half-molds (26, 27) are joined together, liquid thermoplastic is introduced into the cavity (32), the joining step (205) being carried out by cooling the thermoplastic injected into the mold cavity (32).

9. Coated plastic part (1) intended to be integrated within a passenger compartment, the plastic part comprising a base part (2) and a sheet (3), the base part (2) and the sheet being integral one from the other, the coated plastic part (2) being obtained according to the method of any one of claims 1 to 8.

10. Coated plastic part (1) according to the preceding claim, characterized in that the sheet (3) is an active sheet comprising at least one useful surface (11) provided with at least one sensor.

11. Coated plastic part (1) according to claim 9, characterized in that the sheet (3) is a passive sheet comprising at least one visual coating, for example to represent a pattern, a logo, a pictogram or any other decorative means.

12. Motor vehicle comprising a coated plastic part (1) according to any one of claims 9 to 11.