WO2011018803A1

WO2011018803A1 - Covering panel and method of moulding thereof

Info

Publication number: WO2011018803A1
Application number: PCT/IT2009/000377
Authority: WO
Inventors: Fabio Fiammengo
Original assignee: Uniteam Italia S.R.L.
Priority date: 2009-08-11
Filing date: 2009-08-11
Publication date: 2011-02-17

Abstract

Injection moulded covering panel (4) comprising a panel body (8) suitable for being joined to said support, the panel body (8) having a front side (16) to which a covering element (20) is joined and a, rear side (24) able to interface at least partially with the support to be covered. Covering element (20) comprising at least two components (28,32) moulded separately and cohesive with each other: the first moulded component (28) comprising a number of protuberances (36) moulded in one piece with a common base (40) and separated from each other by a number of cavities (44) communicating with each other, the second moulded component (32) comprising a number of filler elements (48) which occupy the cavities (44) between the protuberances (36) of the first moulded component (28).

Description

DESCRIPTION

"COVERING PANEL AND METHOD OF MOULDING THEREOF"

[0001] The present invention relates to a covering panel, specifically obtained by injection moulding and moulding method thereof .

[0002] The production of injection moulded components, such as covering panels or inserts which, on the visible side, have aesthetic decorations of various types, is known in the art . [0003] The decorations in the known art are usually obtained by photoengraving. This technique has a number of disadvantages and drawbacks due mainly to the high costs and to the fact that the graphic forms which can be produced are made on pieces in a single photoengraved material. So, as well as the high production costs, pieces with graphic motifs in two different colours, for example, cannot be made.

[0004] It is also known of to ink print graphic motifs directly onto the finished piece: however over time these printed motifs tend to wear off and deteriorate. In any case, the surface of the piece remains essentially smooth and the aesthetic and tactile effect of a fabric, for example, cannot be obtained.

[0005] In addition, it is known of to mould a covering panel in a single material and then produce a surface decoration by means of embossing. This technique however has the limitation of being used on pieces in a single material and therefore a single colour; in addition the aesthetic effect obtained is not always satisfactory.

[0006] The aim of the present invention is to resolve the drawbacks mentioned with reference to the known technique .

[0007] Such drawbacks and limitations are resolved by a covering panel according to claim 1 and by a moulding method according to claim 9.

[0008] Other embodiments of the panel and of the method according to the invention are described in the further claims.

[0009] Further characteristics and advantages of the present invention will be clearly comprehensible from the description given below of a preferred embodiment, made by way of example and not limited to such, wherein:

[0010] Figure 1 ' shows a front view of a panel according to one embodiment of the present invention ;

[0011] Figure 2 shows a rear view of the panel in figure 1;

[0012] Figures 3A-3C show cross-section views of the panel in figure 1, along the cross-section plane III-III of figure 1, in different phases of injection moulding of the panel ;

[0013] Figure 4 shows a cross-section view of the moulded panel in figure 1, along the cross-section plane IV-IV of figure 2;

[0014] Figure 5 shows an enlarged view of the detail V in figure 4.

[0015] With reference to the above figures, reference numeral 4 globally denotes an injection moulded covering panel, suitable for applying to an associable support (not shown) so as to cover it at least partially.

[0016] The present invention refers to a support of any type, shape, size and/or material. By way of a non- limiting example, the support may be the interior panel of a vehicle, an item of furnishing, a household appliance, a garment and so on.

[0017] The covering panel 4 comprises a panel body 8 suitable for coupling to said support so as to cover it at least partially.

[0018] The coupling between the panel body 8 and the support may be of any type; for example it may be a glued coupling or a shaped coupling, for example slotted.

[0019] According to one embodiment, the panel body 8 comprises coupling elements 12 for attaching to the associable support, said coupling elements 12 being moulded in one piece with the panel body 8. For example, the coupling elements may be holes for the passage of threaded connections or also elastic tabs for a snap coupling with counter-shaped recesses.

[0020] The panel body 8 has a front side 16 to which a covering element 20 is joined, and a rear side 24, opposite the front side 16, able to interface with the support to be covered.

[0021] Advantageously, the covering element 20 comprises at least two moulded components 28, 32, in which each of said components 28, 32 is moulded separately from the other and cohesive with the other, as better described below.

[0022] According to one embodiment, the first moulded component 28 comprises a number of protuberances 36 moulded in one piece with a common base 40 and separated from each other by a number of cavities 44. The cavities 44 communicate with each other; in other words protuberances 36 extend from the base 40 and are arranged so as to form a labyrinth structure in which all the cavities 44 communicate.

[0023] The panel body 8 can be moulded together, that is in one piece, with the first moulded component 28. This way the panel body 8 and the protuberances are one piece with each other. [0024] Preferably, the first moulded component 28 has at least one rear injection hole 46, passing through the base 40, to enable the injection of the second moulded component 32 from the rear side 24 of the panel body 8.

[0025] The second moulded component 32 comprises a number of filler elements 48 which occupy the cavities 44 located between the protuberances 36 of the first moulded component 28. In other words the second moulded component 32 has a complementary shape to that of the first moulded component so as to insinuate itself, during moulding, in all the cavities located between the protuberances of the first moulded component 28.

[0026] The components 28, 32 are moulded with plastic materials compatible with each other so as to ensure the mechanical bonding of the same after moulding; this way after moulding the two components 28, 32 are indissolubly joined to each other and cannot be separated. .

[0027] According to one embodiment, the protuberances 36 of the first moulded component 28 are positioned in the form of a regular and repetitive grid. For example, the protuberances 36 may be positioned like a chessboard so as to partially reproduce the weave of a fabric. According to further embodiments, the protuberances 36 are positioned in non-repetitive grids, or may recreate regular or irregular shapes, for example so as to represent writing, images, symbols and so on.

[0028] According to one embodiment, the filler elements 48 are higher than or the same height as the protuberances 36, when the heights are measured from the common base 40 of the first moulded component 28.

[0029] The difference in height of the components, and in particular between the protuberances 36 and the filler elements, generates a tactile and visual effect similar to a fabric.

[0030] The method of moulding according to the present invention will now be described.

[0031] Specifically, a first injection is made with a first plastic material to mould the panel body 8 and the first component 28. Preferably, with the moulding of the first component, the protuberances 36 in one piece with the base 40 of the panel body 8 are made, said protuberances 36 being separated from each other by a number of cavities 44 communicating with each other (figure 3a) .

[0032] To make the cavities and the protuberance for example a punch and die may be used which identify a first injection chamber reproducing, in negative, the protuberances and the base 40.

[0033] Preferably, following the first injection, the rear injection hole 46 is also made, so as to permit the subsequent injection phase from the rear side 16 of the panel body 8.

[0034] The second injection is then made with a second plastic material to mould the second component 32 (figure 3b) .

[0035] Thanks to the fact that the cavities 44 are communicating, the second injection is able to fill said cavities 44 forming filler elements 48 perfectly cohesive with the protuberances 36 (figure 3c) .

[0036] In fact, advantageously, the second plastic material is compatible with the first plastic material so as to adhere to it after moulding.

[0037] As may be seen from the description, the method of the present invention makes it possible to resolve the drawbacks present in the known technique.

[0038] Advantageously, the piece moulded according to the present invention, once extracted from the mould needs undergo no further processing such as embossing or photoengraving for example, and is therefore ready to be mounted on the associable component.

[0039] This way the times and costs of producing covering panels are considerably reduced.

[0040] The moulded panel is able to reproduce both the aesthetic and tactile effect of a fabric. [0041] In fact, it is possible to use grids which reproduce the effect of a fabric weave, as well as soft plastics which reproduce the soft feel of the fabric.

[0042] In addition, plastics of different colours can be used so as to recreate fabric effects without the need to use inks which would tend to fade over time.

[0043] Advantageously, the components of the panel are compatible with each other so that there is no risk that they will separate in time, in other words that the panel will split.

[0044] In addition, thanks to the compatibility of the materials, the covering panels can be scrapped and pulped without having to first separate the various components.

[0045] The fields of application of the present invention are varied. For example, aesthetic details of vehicles can be made, such as parts of door panels or car pillars, but also covering panels for household appliances, furnishing elements or clothing accessories. [0046] In particular the present invention finds an advantageous application in the car dashboard sector, where the need is felt to cover vehicle interiors with coverings which are, at the same time, both resistant and pleasant to look at and touch. [0047] These characteristics are ensured by the panels of the present invention, given the possibility of using soft plastics which are at the same time resistant to abrasion. In addition, thanks to the cohesion of the different plastic materials injected, the two components are guaranteed not to separate in time as a result of wear and/or the vibrations transmitted by the vehicle.

[0048] A person skilled in the art, may make numerous modifications and variations to the panels and methods described above so as to satisfy contingent and specific requirements

[0049] For example, to make the covering element, more than two components may also be used, using different materials compatible with each other. This way the most varied colour and tactile effects can be created, by modifying, for example, the height and type of the protuberances .

[0050] These and other modifications and variations all fall within the scope of protection of the invention as defined by the following claims.

Claims

1. Injection moulded covering panel (4) , suitable for applying to an associable support, so as to cover it at least partially, comprising

- a panel body (8) suitable for being joined to said support ,

- the panel body (8) having a front side (16) to which a covering element (20) is joined and a rear side (24) , able to interface with the support to be covered at least partially,

characterised in that

the covering element (20) comprises at least two moulded components (28, 32) , each of said components (28, 32) being moulded separately from the other and cohesive with the other,

- the first moulded component (28) comprising a number of protuberances (36) moulded in one piece with a common base (40) and separated from each other by a number of cavities (44) , said cavities (44) communicating one another,

- the second moulded component (32) comprising a number of filler elements (48) which occupy said cavities (44) between the protuberances (36) of the first moulded component (28) .

2. Covering panel (4) according to claim 1, wherein the components (28, 32) are moulded in plastic materials compatible with each other so as to ensure adhesion and indissoluble mechanical coupling after moulding.

3. Covering panel (4) according to claim 1 or 2, wherein the panel body (8) is moulded in one piece with the first component (28) .

4. Covering panel (4) according to any of the previous claims, wherein the protuberances (36) of the first moulded component (28) are positioned in a regular and repetitive grid pattern.

5. Covering panel (4) according to any of the previous claims, wherein the filler elements (20) are of the same height or greater height than the protuberances (36) , such heights being measured from the common base (40) of the first moulded component (28) .

6. Covering panel (4) according to any of the previous claims, wherein the first moulded component (28) has at least one rear injection hole (46) , passing through the common base (40) , to permit the injection of the second component (32) from the rear side (24) of the panel body (8).

7. Covering panel (4) according to any of the previous claims, wherein the panel body (8) comprises coupling elements (12) for coupling of the associable component, said coupling elements (12) being moulded in one piece with the panel body (8) .

8. Covering panel (4) according to any of the previous claims, wherein said panel (4) is an interior covering panel for vehicles .

9. Method of moulding a covering panel (4) according to any of the claims from 1 to 8, comprising the phases of:

- making a first injection with a first plastic material to mould the panel body (8) and the first moulded component (28) , the first moulded component (28) comprising a number of protuberances (36) which extend from the base (40) of the panel body (8) , said protuberances (36) being separated from each other by a number of cavities (44) communicating with each other,

- making a second injection with a second plastic material to mould the second component (32) , the second injection filling the cavities (44) located between the protuberances (36) of the first moulded component (28) , - wherein the second plastic material is compatible with the first plastic material so as to adhere to it after moulding .

10. Moulding method according to claim 9, wherein following the first injection, at least one rear injection hole is made (46) passing through the panel body (8) so as to put the front side (16) and the rear side (24) of the panel body (8) into communication with each other, and wherein the second injection is made through said injection hole (46) from the rear side (24) of the panel body (8) .