FR3106293A1 - A method of manufacturing a vehicle wrapping part and corresponding vehicle wrapping part - Google Patents

Abstract

Method of manufacturing a vehicle trim part and corresponding vehicle trim part The manufacturing method comprises inserting at least one ventilation insert (10) into a trim element (4, 6), the ventilation insert (10) being permeable and/or porous so as to let the gases pass and/or store the gases and prevent the passage of a foam, and the molding of a foam lining (8 ) against the covering element (4, 6), so that gases escape into and/or via the ventilation insert (10) during the molding of the foam, the foam remaining blocked by the insert ventilation (10). Figure for the abstract: Figure 2

Description

Method of manufacturing a vehicle trim part and corresponding vehicle trim part

The present invention relates to the field of vehicle trim parts, in particular motor vehicles.

A vehicle trim part is generally arranged inside the vehicle, for reasons of comfort and aesthetics.

It is possible to provide a trim piece comprising a substrate defining the general shape of the trim piece, a skin covering the substrate and defining the visible surface of the trim piece, and a foam lining interposed between the substrate and the skin to impart a soft feel to the trim piece.

Such a trim part is produced for example by positioning the substrate and the skin in a mold, then by molding foam between the substrate and the skin to form the foam lining.

During the molding of the foam, gases present in the mold and/or generated by the foaming of the foam are evacuated via vents made in the mold, so that these gases are not trapped and do not prevent the correct distribution foam between the substrate and the skin.

However, such a mold is expensive to design and produce, and has a limited lifespan.

One of the aims of the invention is to propose a method of manufacturing a vehicle trim part comprising a foam trim, which is easy and economical to produce.

To this end, the invention proposes a method of manufacturing a vehicle trim part comprising a trim element and a foam trim, the manufacturing method comprising the insertion of at least one ventilation insert in the covering element, the ventilation insert being permeable and/or porous so as to let the gases pass and/or store the gases and prevent the passage of the foam, and the molding of the foam lining against the covering element, so that gases escape into and/or through the ventilation insert during the molding of the foam, the foam remaining blocked by the ventilation insert.

The provision of at least one permeable and/or porous ventilation insert on a trim element of the trim piece against which the foam lining is formed, allows the evacuation of gases in and/or via the insert ventilation while blocking the passage of foam.

It is no longer necessary to provide a vent in the mold, which makes it possible to simplify the mold and improve its life since it does not have a vent likely to be damaged and/or clogged by foam over time.

The ventilation insert provided on a cladding element of a cladding part serves as a kind of single-use vent for the cladding part.

According to particular embodiments, the manufacturing process comprises one or more of the following optional characteristics, taken individually or according to all technically possible combinations:

- the trim element provided with the ventilation insert is a substrate, the trim part further comprising a covering, the foam lining being molded between the substrate and the covering;

- the covering is also provided with a permeable and/or porous ventilation insert so that the gases are evacuated in or via this ventilation insert during the molding of the foam, the foam remaining blocked by this ventilation insert.

- the covering has no ventilation insert;

- the trim element provided with the ventilation insert is a coating, the trim part further comprising a substrate, the foam lining being molded between the coating and the substrate;

- the substrate is devoid of a ventilation insert;

- the manufacturing process comprises, after the molding of the foam insert against the trim element provided with a ventilation insert, the addition of another trim element so that the foam insert is located between the trim element provided with the ventilation insert and the other trim element;

- the trim element provided with the ventilation insert is a substrate, the other trim element being a coating.

The invention also relates to a vehicle trim part comprising a trim element and a foam trim overmoulded on the trim element, the trim element being provided with a permeable ventilation insert and/or porous capable of letting through and/or storing gases, the ventilation insert being obstructed by the foam lining.

According to particular embodiments, the trim part comprises one or more of the following optional characteristics, taken individually or in any technically possible combination:

- the trim element provided with the ventilation insert is a substrate or a coating of the trim part;

- it further comprises another trim element, the foam trim being located between the trim element provided with the ventilation insert and the other trim element;

- the other trim element is also provided with a permeable and/or porous ventilation insert capable of letting through and/or storing gases, the ventilation insert being obstructed by the foam lining;

- the covering element provided with the ventilation insert is a substrate or a covering, the other covering element being respectively a covering or a substrate.

The invention also relates to a motor vehicle provided with a trim part as defined above.

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

- Figure 1 is a schematic sectional view of a trim piece for a vehicle;

- Figure 2 is a schematic sectional view of a mold during manufacture of the trim part of Figure 1;

- [Fig 4] Figures 3 and 4 are schematic sectional views of vehicle trim parts; And

- [Fig 6] Figures 5 and 6 illustrate steps in a method of manufacturing a trim part.

The trim piece 2 in Figure 1 is a vehicle interior trim piece, in particular a motor vehicle.

The trim part 2 is for example a center console trim part, a dashboard trim part, a door trim trim part, a seat trim part, a armrest trim, one piece of roof lining, one piece of glove box trim, etc.

In the example illustrated in Figure 1, the covering part 2 comprises two covering elements, namely a substrate 4 and a covering 6, and a foam filling8 interposed between the substrate 4 and the covering6.

Foam liner 8 is in contact with substrate 4 and liner 6. In particular, foam liner 8 is molded between substrate 4 and liner 6.

The trim part 2 here has a multilayer structure, comprising three superimposed layers formed by the substrate 4, the foam 8 and the coating 6.

The substrate4 defines the curve of the trim part 2, i.e. the shape of the vehicle trim 2, in particular the three-dimensional shape of the trim part 2.

The substrate has a front face 4A facing the side of the coating 6 and a rear face 4B opposite the front face 4A.

The coating 6, also called "skin" or "appearance skin", defines the visual appearance of the trim piece 2, i.e. the visible part of the trim piece 2 when the trim piece 2 is mounted in the vehicle. Coating 6 also defines the feel of trim piece 2.

Coating 6 comprises a front face 6A facing away from substrate 4 and a rear face 6B opposite front face 6A and facing substrate 4. Front face 6A of coating 6 is the visible face of coating 6.

The coating 6 is for example made of PVC (polyvinyl chloride), TPU (thermoplastic polyurethane), TPO (unvulcanized thermoplastic elastomer), natural or synthetic leather or TEP (plastic-coated fabric), the plastic of coating of the TEP being for example TPO, TPU or PVC.

The foam lining 8 is for example configured to impart a soft touch to the vehicle trim 2. The expression "soft touch" means here that the covering 6 is deformable to the touch, that is to say deformable in a sensitive when one presses with a finger on the coating 6. The foam filling 8 is for example made of a PUR (polyurethane) foam.

The trim piece 2 comprises at least one ventilation insert 10 arranged on a trim element against which the foam lining 8 is applied, and in particular molded.

The ventilation insert 10 is for example placed in an orifice 11 made in the trim element receiving the ventilation insert 10.

The orifice 11 is advantageously through. It opens onto two opposite faces of the trim element, one of these two faces preferably being in contact with the foam lining 8.

The ventilation insert 10 disposed in an orifice 11 has for example a thickness equal to or less than that of the covering element receiving the ventilation insert 10 at the level of the orifice 11 in which the ventilation insert is received. 10.

In the example of Figure 2, the trim piece 2 comprises a ventilation insert 10 disposed on the substrate 4. The ventilation insert 10 is here disposed in an orifice 11 which is through and which opens onto the front face 4A and the rear face 4B.

The ventilation insert 10 here has a thickness substantially equal to that of the substrate 4. It is therefore flush with the rear face 4B and the front face 4A of the substrate 4. In a variant, it has a thickness strictly less than that of the substrate 4.

The ventilation insert 10 is configured to allow the gases to pass and/or to store the gases, and to block the foam constituting the foam lining 8 during the molding of the latter.

The ventilation insert 10 is made of a permeable and/or porous material. The permeability of the material allows gases to pass while blocking the foam. The porosity of the material makes it possible to store the gases in the porosities of the material (the gases can penetrate into the ventilation insert 10) while blocking the foam (the foam cannot penetrate into the ventilation insert 10).

A person skilled in the art will know how to choose the permeable and/or porous material constituting the ventilation insert 10, for example the porosity and/or the pore sizes of the ventilation insert 10, allowing, during molding, to let through the gases while retaining the foam constituting the foam filling 8.

A permeable and/or porous material which may be suitable is, for example, a foam, in particular low-density polyurethane foam, or an agglomerated or compressed material, in particular a ceramic, polystyrene, expanded polypropylene (or EPP for “Expanded Polypropylene”) in English).

In a particular example, the ventilation insert 10 is made of a material consisting of a polyurethane foam, in particular a polyurethane foam having a density of between 50 kg/m ³ and 250 kg/m ³ .

Advantageously, the ventilation insert 10 has pores having dimensions less than 1 μm and/or a permeability of between 20 and 100 lm ^-2 .s ^-1 (liter per square meter and per second) under a pressure of 100 Pa (Pascal).

A method of manufacturing the trim part 2 of Figure 1 is illustrated in Figure 2.

The manufacturing process comprises the supply of the substrate 4 provided with the ventilation insert 10 and the coating 6, their positioning in a mold 12, and the molding of the foam M between the substrate 4 and the coating 6 to obtain the gasket in foam8 (Figure 1).

The mold 12 comprises two mold parts 14, 16. The substrate 4 and the coating 6 are each placed against a respective mold part 14, 16, and the foam 8 is formed between the substrate 4 and the coating 6. The foam M s applied against the front face 4A of the substrate 4 and against the rear face 6B of the coating 6.

The foam M is for example inserted into the mold 12 before the mold 12 is closed or injected into the mold after the mold 12 is closed.

The foam M is for example a two-component foam formed from the mixture of two components which foam when they are mixed together. This is referred to as a “foaming reaction” or more simply “foaming”.

During foaming, the volume of the foam increases, so that the foam fills the space available in the mold 12, and which is here delimited between the substrate 4 and the coating 6.

The presence of the ventilation insert 10 arranged on a covering element, here on the substrate 4, allows the gases present in the mold 12 to escape into and/or via the ventilation insert 10 arranged on this element. of dressing.

This prevents gas from being trapped in the foam and impairs manufacturing quality, for example due to a trapped gas bubble in which the foam would not be present.

The part of the mold against which the covering element provided with the ventilation insert 10 is applied, here the part of the mold 14 against which the substrate 4 provided with the ventilation insert 10 is applied, is optionally provided with a duct 18 for the passage of gas escaping through the trim element via the ventilation insert 10.

However, it is not necessary to provide the duct 18 with any retaining element to retain the foam M since the foam M is already retained by the ventilation insert 10 integrated into a trim element, namely here the substrate 4.

The presence of a duct 18 is optional, and, in a variant, the part of the mold against which the covering element fitted with the ventilation insert 10 is applied is not fitted with such a duct 18, but is for example full next to the ventilation insert10. The absence of a duct18 further simplifies the mold.

In this case, the gases can penetrate into and be stored in the ventilation insert 10 when the ventilation insert 10 is porous and/or possibly escape between the trim element provided with the ventilation insert 10 and the part of the mold against which this covering element is applied, here the part of the mold 14, when the ventilation insert 10 is permeable.

The trim piece 2 in Figure 1 has two trim elements between which the foam lining 8 is interposed, being molded between the two trim elements, a ventilation insert 10 being placed on one of the two trim elements. trim, no ventilation insert being arranged on the other trim element.

More particularly in the case of the example of Figure 1, the two trim elements are a substrate 4 and a coating 6, the substrate 4 being provided with a ventilation insert 10, the coating 6 being devoid of insert ventilation 10.

This makes it possible in particular to keep the covering 6 intact, given that its front face 6A constitutes the visible face of the covering part 2, avoiding the provision of a ventilation insert 10 on the covering 6.

The invention is not limited to this exemplary embodiment, other exemplary embodiments being possible.

In an exemplary embodiment, a trim part comprising a substrate 4 and a covering 6 is provided with a ventilation insert 10 placed on the covering 6, the substrate 4 having no ventilation insert 10.

The trim part 2 of Figure 3 differs from that of Figure 1 in that the ventilation insert 10 is placed on the coating 6 instead of being placed on the substrate 4.

The manufacturing process in this case is similar to that described with reference to Figure 2, except that the gases escape into and/or via the ventilation insert 10 of the covering 6.

As an option, a duct 18 for the passage of gases can of course be provided on the mold part 16 against which the coating 6 is positioned, to allow the gases to escape via the ventilation insert 10.

The ventilation insert 10 is then likely to open onto the visible front face 6A of the covering 6.

The ventilation insert 10 can be positioned on a portion of the front face 6A of the covering 6 which is hidden once the trim part is mounted on the vehicle, for example because it is covered or applied against another part. adjacent trim.

As an option, the trim piece 2 is fitted with a decorative insert 20 arranged on the front face 6A of the covering 6 and covering the ventilation insert 10.

The decorative insert 20 is for example a decorative medallion. Such a medallion relates, for example, to the make of the vehicle, the vehicle model, the finish of the vehicle, and/or the presence of particular equipment in the vehicle, for example an airbag, an audio system, etc.

In this case, the decorative insert 20 is fixed to the covering 6 after the molding of the foam M, in order to leave the ventilation insert 10 free during the foaming of the foam M.

According to another possibility, the ventilation insert 10 is located on a part of the trim piece 2 intended to be cut after molding the foam trim8.

In an exemplary embodiment, a trim piece 2, comprising two trim elements, for example a substrate 4 and a covering 6, and a foam lining 8 interposed between the two trim elements, is provided with a respective ventilation insert 10 disposed on each of the two trim elements. Each of the two trim elements therefore carries a ventilation insert 10.

During the corresponding manufacturing process, the foam M is molded between the two trim elements to form the foam trim 8.

During this molding, the gases present between the two trim elements escape through each of the ventilation inserts 10.

The mold parts against which the covering elements are arranged are optionally provided with ventilation ducts 10 for the passage of gases, without it being necessary to provide a device for blocking the foam M in these ventilation ducts 18, the foam being retained by the ventilation inserts 10.

The trim part 2 in Figure 4 is consistent with this embodiment and differs from that in Figure 1 in that it comprises a respective ventilation insert 10 arranged on each of the substrate 4 and the coating 6.

The manufacturing process in this case is similar to that described with reference to Figure 2, except that the gases escape in and/or via the ventilation inserts 10 placed in the substrate 4 and the coating 6,

A conduit 18 for the passage of gases can of course be provided as an option on each of the mold parts 14, 16 receiving the trim elements.

In an exemplary embodiment, the foam M is molded against a single trim element provided with a ventilation insert 10 to form the trim 8. Optionally, after molding the foam M, another trim element is added to the assembly formed by the trim element provided with the insert and the foam lining 8, so that the foam lining 8 is located between the two trim elements.

This makes it possible, for example, to form a trim part with a delicate trim element which could be damaged by the molding of a foam against this trim element and/or which must be mounted in a particular material.

In one example, the covering element provided with the ventilation insert 10 and on which the foam M is molded is a substrate, and the other covering element is a covering, in particular a covering made of natural leather or synthetic, which is for example mounted by being stretched on the substrate.

The manufacturing process illustrated in Figure 5 differs from that of Figure 2 in that the foam M is molded on the substrate 4 provided with the ventilation insert 10.

The substrate 4 is inserted into the mold 12, more precisely against the mold part 14, then the foam M is molded between the substrate 4 and the other mold part 16, the gases present in the molding cavity, which is defined here between the substrate 4 and the other mold part 16, escaping into and/or screw the ventilation insert 10 disposed in the substrate4.

Optionally, as illustrated in Figure 6, a covering 6 is then attached to the substrate 4 provided with the foam lining 8, so that the foam lining 8 is interposed between the substrate 4 and the covering 6.

The covering part 2 thus obtained is similar to that of Figure 1.

In the embodiments described, for reasons of simplification and clarity, each trim element (substrate 4 and covering 6) is provided with a single ventilation insert 10.

Of course, in general, each trim element provided with a ventilation insert can in practice be provided with several ventilation inserts 10, each ventilation insert 10 being permeable and/or porous so as to allow gases to pass and /or store gases and prevent the passage of foam

Each trim element (for example a substrate 4 or a covering 6) provided with a ventilation insert 10 is provided with at least one ventilation insert 10, i.e. one or more ventilation insert(s) 10 , each ventilation insert 10 being configured to pass and/or store gases and block the foam M of the foam liner 8 during the molding of the foam liner 8 against the trim element.

Furthermore, in general, each ventilation insert 10 is preferably placed in an orifice 11 of the corresponding trim element, preferably in a through orifice 11 of this trim element.

In addition, each ventilation insert 10 has a thickness equal to or less than that of the covering element, in particular at the level of the orifice in which the ventilation insert 10 is received.

Also generally, the location of each ventilation insert 10 on the corresponding trim element is chosen according to the geometry of the trim part 2 to be manufactured, so as to be located in an area where there is a risk of formation of a gas pocket during the molding of the foam lining 8 (for example a high point, a closed zone, a meeting zone of two foam fronts, etc.).

Claims (10)

Method of manufacturing a vehicle trim part comprising a trim element (4, 6) and a foam trim (8), the manufacturing method comprising inserting at least one ventilation insert (10 ) in the covering element (4,6), the ventilation insert (10) being permeable and/or porous so as to let the gases pass and/or store the gases and prevent the passage of the foam, and molding the foam insert (8) against the trim element (4, 6), so that gases escape into and/or through the ventilation insert (10) during the molding of the foam, the foam remaining blocked by the ventilation insert (10). Manufacturing process according to claim 1, in which the trim element provided with the ventilation insert (10) is a substrate (4), the trim piece (2) further comprising a coating (6), the foam liner (8) being molded between the substrate (4) and the liner (6). Manufacturing process according to claim 1, in which the trim element provided with the ventilation insert (10) is a coating (6), the trim part (2) further comprising a substrate (4), the foam liner (8) being molded between the liner (6) and the substrate (4). Manufacturing process according to claim 1, comprising, after the molding of the foam lining (8) against the covering element (4) provided with a ventilation insert (10), the addition of another element covering (4) so that the foam filling (8) is located between the covering element (4) provided with the ventilation insert (10) and the other covering element (6). Manufacturing process according to claim 4, in which the covering element provided with the ventilation insert (10) is a substrate (4), the other covering element being a coating (6). Vehicle trim part comprising a trim element (4, 6) and a foam trim (8) molded over the trim element (4, 6), the trim element (4,6) being provided with a permeable and/or porous ventilation insert (10) capable of allowing gases to pass and/or storing gases, the ventilation insert (10) being obstructed by the foam lining (8). Trim part according to Claim 6, in which the trim element provided with the ventilation insert (10) is a substrate (4) or a coating (6) of the trim part (2). Trim part according to claim 6 or claim 7, further comprising another trim element (6), the foam insert (8) being located between the trim element provided with the ventilation insert (10 ) and the other covering element (6). Trim part according to Claim 8, in which the trim element provided with the ventilation insert is a substrate (4) or a covering (6), the other trim element being respectively a cover (6 ) or a substrate (4). Motor vehicle fitted with a trim piece according to any one of claims 6 to 9.