Process for the manufacture of trim panels for motor-vehicles

Abstract: Panels for interiors of motorvehicles are manufactured by producing first of all by injection molding a panel (7) presenting missing portions with predetermined area and shape, said molding involving the simultaneous injection of a surface coating layer and of an internal supporting layer, by separately producing a plurality of portions of panel (8') having area and shape substantially corresponding to those of said missing portions and fastening said separately produced portions (8') to said panels (7).

Description: The present invention relates to a process for the manufacture of trim panels for motorvehicles and to a mold for performing such a production as described in EP-A-0290399. Many types of processes are known for the manufacture of trim panels for interiors of motorvehicles. Generally, said processes envisage to produce first of all the base portion of the panel and then to apply additional elements thereon such as door handles and pockets, that are prepared by separate operation. Furthermore, methods are known envisaging to directly obtain a base portion provided with areas covered with a fabric to improve the general appearance of the panel. Said solution, which allows to avoid the subsequent application of small panels covered with fabric, has been described, with different features, in several patent applications in the name of the present applicant. The object of the present invention is to propose a process that enables the manufacture of trim panels with a reduced number of operations and therefore reduced manufacturing costs. Said object is obtained by means of the present invention that relates to a process for the manufacture of trim panels for interiors of motorvehicles as defined in claim 1. A further object of the present invention is a mold for carrying out a process of the afore described type, characterized in that it comprises half-molds provided with projecting portions in contact with each other when the mold is closed, at least in correspondence to the portions of panel presenting an undercut in the finished panel. A further object of the present invention consists in panels obtained with the claimed process in claim 8 and in the panel semifinished elements according to claim 10. An embodiment of the invention will be now described in a more detailed way with reference to the accompanying drawings given by illustrative and non limiting purposes, where: figure 1 is a side sectional view of a mold to be used in the process according to the invention; figure 2 is a partial view of the transverse section of the mold of figure 1; figure 3 is a side sectional view of a partially formed panel; figure 4 is a side sectional view of a finished panel; figure 5 is a perspective view of a panel such as that in figure 4; and fig. 6 is a side sectional view of a further embodiment of a panel according to the invention. It is hereby specified that the term " trim panel" and "panel for interiors" as used herein means, besides the panels for doors, any type of element for motorvehicles internal trimming such as dashboard, heel-posts, hat shelves, and so on. Figure 1 shows in side section a mold suitable to be used for the method according to the invention, and reference thereto will be initially made to describe said process. As previously mentioned, the process according to the invention envisages first of all to form in the mold 1 a partial structure of panel by simultaneously injecting a material for external coating, i.e. the so called imitation leather of the panel, and a material for internal support that is preferably consisting of polypropylene with sawdust filler, known in the art under the name of Woodstock. Preferably the material of external coating, too, is of the polypropylene type. By heaving the same kind of inner and auter material, recycling of the panel once the car is disposed of, will be much easier. Examples of materials suitable to be used are the products EXP 1638/3 for the internal portion and EXP 1/162 for the external one, both produced by HIMONT. During the injection of said materials into the cavities 2 of the mold 1, a gas is also preferably injected at predetermined locations of the panel. In particular said gas injection is performed in correspondence to the door handle 3 and the panel pocket 4 and in all points such as ribs or the like where the mass is subject to volume variations that may result in shrinkage cavities. Such gas injection results in empty spaces 11 within the material 10, as disclosed in figures 3, 4 and 6. Figures 1 and 2, for better clarity of the drawing, schematically represent only channels 5 for gas injection in correspondence to handle and pocket, while channels for thermoplastic injection are not disclosed. As better shown in figure 2, the mold 1 presents, on the half-molds, portions 6 which are in contact with each other in order to prevent any panel molding in correspondence to said portions 6. These portions are located at least in correspondence to the areas that in the finished panel will be undercut areas, namely at least in correspondence to the door handle 3 and the pocket 4 and in any case where a decorative element is required. Thus an incomplete panel is obtained, where its base portion 2 is one piece with the handle and the pocket, and which is provided with a plurality of cavities or missing base portions at least in correspondence thereto. The missing base portions have predetermined area and shape, because they have both a technical function, namely to allow the formation of undercut areas (i.e. handle and/or pocket) and a decorative function, namely to form fabric covered areas. Figure 3 shows a side section of the thus obtained panel semi-finished product, where the imitation leather 9 and the sawdust filled internal material 10 are disclosed. The missing portions of panel are produced separately, and generally consist of panels 8 preferably consisting of or covered with a material different from the one used for the external coating of the semi-finished product 7. Said panels 8 will have area and shape complementary and substantially corresponding to those of the portions missing on the semi-finished product 7. The term "substantially corresponding" means that panels 8 are provided with flanges or edges allowing their fastening to the semi-finished product 7 for the panel completion. All complementary panels 8 for one semi-finished product 7 may be obtained in a single piece panel 8 (fig. 6). Preferably, complementary panels 8 will be of the type covered with fabric and will therefore constitute the fabric medals that in the known technique are generally obtained in a single piece with the imitation leather coating. The technique of simultaneous injection of coating 9 and internal material 10 is known per se, as are known the techniques of localized gas injection during the injection of a thermoplastic material as well as the molding of panels coated with fabric. For example, these latter can be obtained by the injection molding of a thermoplastic support on a coating fabric, as described in the Italian application n. MI91A000257 filed by the Applicant on 01 February, 1991. After fastening complementary panels 8 to the semi-finished product 7, the finished panel schematically shown in figures 4, 5 and 6 is obtained . Fig. 6 discloses a further embodiment of a trim panel according to the invention. In this embodiment, besides pocket 4 and handle 11, there is also an armrest 15. In this case missing base portions are obtained from a single complementary panel 8' consisting of a supporting element 12 and a cover element, e.g. made of fabric, 13, provided on the front face of panel 8'. Complementary panel 8' is secured to semi-finished panel 7 by securing means 14 such as screws at any suitable means known in the art. The economical and esthetic advantages of the process according to the invention are evident. In fact, it is possible to obtain door handles and pockets in a single piece with the panel, thus avoiding their separate production and their subsequent fastening to the panel by means of screws. Furthermore, the separate manufacture of one or several panels 8 allows to obtain in the finished panel the so-called "shadow effect", usually given by the presence of a fabric panel separate from the bottom panel, otherwise very hardly obtainable.

Claims: A process for manufacturing trim panels for interiors of motorvehicles, comprising the injection molding of a first panel portion (2) with missing base portions having predetermined area and shape, separately preparing one or more complementary panel portions (8) having area and shape substantially corresponding to those of said missing base portions; and fastening said complementary panel portions to said first panel, characterized in that said first panel portion is obtained by coinjection moulding of an internal support material and a coating material to form a base panel having an internal supporting material (10) surrounded by a coating material (9). A process according to claim 1, wherein said first panel portion is one-piece with handle and/or pocket or similar undercut parts said missing base portions are provided in correspondence to said handels (11), pockets (4) or similar undercut parts. A process according to claim 1 or 2, wherein gas is injected into said supporting material of said first panel portion in correspondence to said door handles (11) and/or pockets (4) and/or ribs or other parts of the panel subject to volume variations upon cooling of said panel material. A process according to claim 1, wherein an external polypropylene coating and an internal polypropylene support comprising sawdust filler are simultaneously injected. A process according to claim 1, wherein said complementary panels are comprising a fabric outer cover. A process according to claim 5, wherein said complementary panels (8) are obtained by injection molding of a thermoplastic support on a fabric portion. A mold to perform a process according to one of the claims 1 to 6, characterized in that it comprises half-molds provided with portions (6) in contact with each other when the mold is closed at least in correspondence to the portions of panel presenting an undercut when the panel is finished. A panel for interiors of motorvehicles, as obtainable by means of a process according to one of claims 1 to 7, characterized in that it comprises a first panel portion (2) provided with missing base portions and with at least a handle (11) and/or a pocket (4) in one-piece with said first portion, and one or more complementary panel portions (8, 8') bound to said first panel portion (2) in correspondence to cited missing base portions, said first panel portion having an internal supporting material (10) surrounded by an outer coating material (9). A panel according to claim 8, wherein said missing base portions are obtained from a single complementary panel (8'). A semi-finished product (7) for the production of a panel according to claim 8 or 9, characterized in that it comprises a panel portion one piece with a door handle (11) and/or a pocket (4) or similar undercut parts, and missing base portions having predetermined area and shape, said missing portions being located at least in correspondence to said handles (11) and/or pockets (4) or similar portions of panel presenting undercuts when the panel is finished, and in that it is comprising an internal support material (10) surrounded by a coating material (9).

Inventors: VECCHIARINO LUIGI, VECCHIARINO, LUIGI
Applicants: COMMER SPA, COMMER S.P.A.
Application year: 1992
Main classification: B60R13
IPC codes: B29C45, B60J5, B60R13, B29L31, B29C69, B29D99