Patent Description:
It is possible to manufacture such a trim panel using an apparatus comprising a first mold section, with a first surface area and a holding device holding the substrate against the first surface area, and a second mold section, with a second surface area on which the cover sheet is secured using pneumatic pins.

The cover sheet is laminated on the substrate by moving the first mold section against the second mold section, such that the first surface area is pressed against the second surface area.

The behavior of the cover sheet is poorly controlled when the apparatus is closed by moving the first mold section against the second mold section. Material sometimes accumulate in curved or corner areas, creating unwanted folds in the cover sheet. The appearance of the trim part is not satisfactory in this case.

<CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT> and <CIT> describe devices and methods for producing a trim panel in accordance with the preambles of the independent claims. <CIT> and <CIT> describe longitudinal sliders movable with respect to one of the mold sections.

An objective of the invention is to propose an apparatus/ process that does not present said drawback.

The problem is solved by an apparatus for producing a trim panel according to claim <NUM>.

Since an edge of the cover sheet is clamped between the first clamping member and the second clamping member in the clamping position, the cover sheet is properly controlled when the first mold section and the second mold section are moved to the molding position. It is possible to avoid that material accumulates in curved or corner areas, creating unwanted folds in the cover sheet. The appearance of the trim part is improved.

The apparatus may present one or several of the features corresponding to claims <NUM> to <NUM>, considered alone or according to any technically feasible combination.

According to a second aspect, the invention relates to a process according to claim <NUM>.

Other features and advantages of the invention will become apparent when reading the following description, given purely as an example, with regard to the <FIG> showing the successive steps of the process in a schematic manner.

The apparatus <NUM> depicted on the <FIG> is for producing a trim panel <NUM> having at least a substrate <NUM> and a cover sheet <NUM> laminated to said substrate <NUM>.

The trim panel <NUM> is for example used to cover the inner surface of automobile doors, or the dashboard, or any other surface of the cockpit of the vehicle.

The trim panel <NUM> may be a sun visor.

The substrate <NUM> is a panel of a substantially rigid material. It is typically made of a plastic material such as Acrylonitrile Butadiene Styrene (ABS), Polycarbonate/Acrylonitrile Butadiene Styrene (PC/ABS), Polyproylene (PP).

The cover sheet <NUM> is a decorative sheet, visible for the passengers of the vehicle.

The cover sheet <NUM> has a decorative layer, typically made of a plastic material, a textile, a leather or a genuine material such as wood, stone. Advantageously, the cover sheet <NUM> comprises a foam backing arranged on the back of the decorative layer.

The cover sheet <NUM> is flexible and can be folded when exerting a pressure of average magnitude.

The first surface area <NUM> has the shape required for the inner surface of the trim part. The inner surface is the surface typically turned opposite the cockpit of the vehicle and not visible by the passengers.

The holding device <NUM> is for example a vacuum device, or a mechanical clamping device, or any other device adapted for holding the substrate <NUM> against the first surface area <NUM>.

The second surface area <NUM> has the shape required for the outer surface of the trim part. The outer surface is the surface typically turned toward the cockpit of the vehicle and visible by the passengers.

The first surface area <NUM> has a shape complementary of the shape of the second surface area <NUM>. It means that the first surface area <NUM> can fit against the second surface area <NUM> with a little or no spacing between them.

In the example, the first surface area <NUM> is convex, and the second surface area <NUM> is concave.

The main drive <NUM> is for example an hydraulic cylinder, or a pneumatic cylinder, or any other type of actuator.

The main drive <NUM> typically moves the first mold section <NUM> with respect to the second mold section <NUM> longitudinally between the molding position and the open position.

The longitudinal direction L is shown on the figures.

In other words, the second mold section <NUM> is fixed, and the first mold section <NUM> is moved by the main drive <NUM>. According to an alternative embodiment, the first mold section <NUM> is fixed, and the second mold section <NUM> is moved by the main drive <NUM>. According to another alternative embodiment, the first mold section <NUM> and the second mold section <NUM> are moved by the main drive <NUM>.

Typically, the first mold section <NUM> moves in translation with respect to the second mold section <NUM> between the molding position and the open position, along the longitudinal direction shown on the figures.

According to an alternative embodiment, the displacement of the first mold section is not a translation. It is a rotation or a combination of translation(s) and rotation(s).

The first surface area <NUM> and the second surface area <NUM> are pressed against one another with the substrate <NUM> and the cover sheet <NUM> between them in the molding position (<FIG>).

The first surface area <NUM> and the second surface area <NUM> are away from one another in the open position (<FIG> and <FIG>).

In the open position, the first surface area <NUM> and the second surface area <NUM> are located one in front of the other.

The clamping frame <NUM> comprises a first clamping member <NUM>, a second clamping member <NUM> and a clamping drive <NUM> moving the first clamping member <NUM> and the second clamping member <NUM> with respect to one another between a cover sheet clamping position (<FIG> and <FIG>) and a cover sheet release position (<FIG>).

An edge <NUM> of the cover sheet <NUM> is clamped between the first clamping member <NUM> and the second clamping member <NUM> in the clamping position.

The edge <NUM> of the cover sheet <NUM> is free with respect to the first clamping member <NUM> and/or the second clamping member <NUM> in the release position.

The first clamping member <NUM> is a frame.

It has a substantially closed contour, and surrounds an empty space. It is arranged around the first mold section <NUM>, as shown on the figures.

The second clamping member <NUM> has a substantially closed contour. It surrounds an empty space. It is arranged around the second surface area <NUM>, as shown on the figures.

The first clamping member <NUM> has a first clamping surface <NUM>.

The second clamping member <NUM> has a second clamping surface <NUM>.

The first clamping surface <NUM> and the second clamping surface <NUM> clamp the edge <NUM> of the cover sheet <NUM> between them in the clamping position (<FIG>).

The first clamping surface <NUM> is turned longitudinally in one direction, toward the second clamping section <NUM>. The second clamping surface <NUM> is turned longitudinally in the opposite direction.

When the first mold section <NUM> and the second mold section <NUM> are in the open position, the cover sheet <NUM> extends between the first surface area <NUM> and the second surface area <NUM> in the clamping position of the clamping frame <NUM>.

The clamping drive <NUM> is typically a pneumatic or hydraulic cylinder or any other type of actuator.

The clamping drive <NUM> moves the first clamping member <NUM> longitudinally in translation with respect to the second clamping member <NUM>.

The clamping frame <NUM> is arranged for adjusting the clamping force by which the edge <NUM> of the cover sheet <NUM> is clamped between the first clamping member <NUM> and the second clamping member <NUM> in the clamping position.

The clamping frame <NUM> comprises for this purpose an adjustable stopper <NUM>, able to adjust the spacing between the first clamping surface <NUM> and the second clamping surface <NUM> in the clamping position.

The adjustable stopper <NUM> comprises for example one or several screws, mounted on the first clamping member <NUM>. The or each screw protrudes longitudinally with respect to a lower surface <NUM> of the first clamping member <NUM> turned tower the second clamping member <NUM>. The height by which the or each screw protrudes is adjustable. In the clamping position, the adjustable stopper <NUM> is in abutment against an upper surface <NUM> of the second clamping member <NUM>.

Changing the position of the screws with respect to the lower surface <NUM> allows changing the longitudinal position of the first clamping member <NUM> with respect to the second clamping member <NUM> in the clamping position, and thus the longitudinal position of the first clamping surface <NUM> with respect to the second clamping surface <NUM> in the clamping position. This in turn allows changing the longitudinal spacing between the first clamping surface <NUM> and the second clamping surface <NUM> in the clamping position.

The clamping force by which the edge <NUM> of the cover sheet <NUM> is clamped between the first clamping member <NUM> and the second clamping member <NUM> in the clamping position can be adjusted as well by changing the force applied by clamping drive <NUM>.

Another possibility for adjusting said clamping force is using supplements arranged between the clamping drive <NUM> and the first clamping member <NUM>. A supplement is spacer having a reduced thickness, arranged between the piston of the cylinder and the first clamping member <NUM>, for example a washer or a plate. Adding or removing one or several supplements allows changing the longitudinal position of the first clamping surface <NUM> with respect to the second clamping surface <NUM> in the clamping position and thus the longitudinal spacing between the first clamping surface <NUM> and the second clamping surface <NUM>.

The first mold section <NUM> comprises a main part <NUM> defining a main area <NUM> of the first surface area <NUM>, and at least one longitudinal slider <NUM> movable with respect to the main part <NUM> between an extended position (<FIG>) and a retracted position (<FIG> and <FIG>).

The at least one longitudinal slider <NUM> is displaced with respect to the main part <NUM> by an actuator, not shown on the figures. The actuator is typically a cylinder, pneumatic or hydraulic.

The or each longitudinal slider <NUM> defines a first surface edge area <NUM> of the first surface area <NUM> in the extended position.

The or each longitudinal slider <NUM> is retracted longitudinally away from the first surface area <NUM> in the retracted position.

The or each longitudinal slider <NUM> is for folding the edge of the cover sheet <NUM> around the free edge of the substrate <NUM>, as will be described further down.

For that purpose, the second clamping member <NUM> comprises at least one transverse slider <NUM>, movable with respect to the second mold section <NUM> between an outer position (<FIG>) and an inner position (<FIG>).

The or each transverse slider <NUM> in the inner position extends longitudinally in front of the at least one longitudinal slider <NUM> when the first mold section <NUM> is in the molding position with respect to the second mold section <NUM> and the at least one longitudinal slider <NUM> is in the retracted position.

More specifically, when the first mold section <NUM> is in the molding position with respect to the second mold section <NUM> and the at least one longitudinal slider <NUM> is in the extended position, the first surface edge area <NUM> is pressed against a corresponding area <NUM> of the second surface area <NUM> (<FIG>).

When the first mold section <NUM> is in the molding position with respect to the second mold section <NUM> and the at least one longitudinal slider <NUM> is in the retracted position, a cavity <NUM> is created in the first mold section <NUM> for receiving the transverse slider <NUM> in the inner position (<FIG>).

The or each transverse slider <NUM> in the outer position does not extend longitudinally in front of the at least one longitudinal slider <NUM>. It does not extend, longitudinally, in front of the second surface area <NUM>.

Advantageously, the or each transverse slider <NUM> defines a part of the second clamping surface <NUM>.

As shown on the figures, the second surface area <NUM> is a depression, surrounded by an upper edge <NUM> having a closed contour.

Typically, a part of the second clamping member <NUM> is made by at least one portion of the upper edge <NUM>, and another part of the second clamping member <NUM> is made by the or each transverse slider <NUM>.

A part of the second clamping surface <NUM> is made by at least one portion of the upper edge <NUM>, and another part of the second clamping surface <NUM> is made by the or each transverse slider <NUM>.

For example, if the second clamping member <NUM> comprises several transverse sliders <NUM>, the second clamping member <NUM> comprises several portions of the upper edge <NUM>, separated from one another by the transverse sliders <NUM>.

The process for producing the trim panel <NUM> will be detailed below.

The process is designed for being implemented using the apparatus <NUM> described above. Conversely, the apparatus <NUM> is particularly adapted for carrying out the process detailed below.

The process comprises the following steps:.

The main drive <NUM> moves the first mold section <NUM> with respect to the second mold section <NUM> longitudinally between the molding position and the open position.

The first mold section <NUM> is as described above.

The clamping frame <NUM>, the first clamping member <NUM> and the second clamping member <NUM> are as described above.

The step of arranging the substrate <NUM> against the first surface area <NUM> and the step of arranging the cover sheet <NUM> in the clamping frame <NUM> are carried out with the first mold section <NUM> and the second mold section <NUM> in an open position with respect to one another.

The first surface area <NUM> and the second surface area <NUM> are away from one another in the open position, as shown in the <FIG>.

The substrate <NUM> is arranged against the first surface area <NUM> by mean of a holding device <NUM>. The holding device <NUM>, as described above, is for example a vacuum device, or a mechanical clamping device.

The cover sheet <NUM> is arranged in the clamping frame <NUM> as shown in the <FIG> and <FIG>.

The first clamping member <NUM> and the second clamping member <NUM> are initially in a release position with respect to one another (<FIG>). The first clamping member <NUM> and the second clamping member <NUM> are longitudinally away from one another.

The cover sheet <NUM> is secured to the second clamping member <NUM>, for example using pins (not shown on the figures) arranged on the second clamping surface <NUM>.

Then, the first clamping member <NUM> and the second clamping member <NUM> are brought to a cover sheet clamping position with respect to one another (<FIG>).

The first clamping member <NUM> is moved longitudinally with respect to the second clamping member <NUM>.

The first clamping member <NUM> stops when the adjustable stopper <NUM> comes in abutment against the upper surface <NUM> of the second clamping member <NUM>.

The edge <NUM> of the cover sheet <NUM> is clamped between the first clamping member <NUM> and the second clamping member <NUM> in the clamping position, and more specifically between the first clamping surface <NUM> and the second clamping surface <NUM>.

The spacing between the first clamping surface <NUM> and the second clamping surface <NUM> in the clamping position is adjusted by mean of the adjustable stopper <NUM>.

It is adjusted as a function of the thickness of the cover sheet <NUM>, and of the clamping force by which the edge <NUM> of the cover sheet <NUM> must clamped between the first clamping member <NUM> and the second clamping member <NUM>.

The adjustable stopper <NUM> is as described above.

In some cases, the edge <NUM> of the cover sheet must be strongly clamped, such that the position of the edge <NUM> does not shift when the first molding section <NUM> and the second molding section <NUM> are brought to the molding position. In other instances, the edge <NUM> of the cover sheet must be less strongly clamped, such that the position of the edge <NUM> is allowed to shift when the first molding section <NUM> and the second molding section <NUM> are brought to the molding position.

Alternatively, or in addition, the clamping force is adjusted by changing the force applied by clamping drive <NUM>, and/or using supplements arranged between the clamping drive <NUM> and the first clamping member <NUM>, as described above.

The molding position is shown on the <FIG>.

The substrate <NUM> and a central part <NUM> of the cover sheet <NUM> are pinched between the first surface area <NUM> and the second area <NUM>. The central part <NUM> of the cover sheet <NUM> covers an outer surface <NUM> of the substrate <NUM>. The edge <NUM> of the cover sheet is clamped between the first clamping member <NUM> and the second clamping member <NUM>.

The edge <NUM> is connected to the central part <NUM> by a folding line <NUM> along which the cover sheet <NUM> is folded.

The process further comprises the following additional steps:.

The or each longitudinal slider <NUM> is as described above.

As described above, the main part <NUM> defines the main area <NUM> of the first surface area <NUM>, the or each longitudinal slider <NUM> defining a first surface edge area <NUM> of the first surface area <NUM> in the extended position.

The or each transverse slide <NUM> is as described above.

As described above, the or each transverse slider <NUM> in the inner position extends longitudinally in front of the at least one longitudinal slider <NUM> when the first mold section <NUM> is in the molding position with respect to the second mold section <NUM> and the at least one longitudinal slider <NUM> is in the retracted position. The or each transverse slider <NUM> in the outer position does not extend longitudinally in front of the at least one longitudinal slider <NUM>.

The situation at the end of the moving step is depicted on the <FIG>. As shown, in the retracted position, a cavity <NUM> is created on the side of the first mold section <NUM>, in front of the transverse slider <NUM>.

Between the moving step and the folding step, the first clamping member <NUM> and the second clamping member <NUM> are brought back to the release position with respect to one another (<FIG>), to release the edge <NUM>.

During the folding step, the or each transverse slider <NUM> is moved substantially perpendicularly to the longitudinal direction L. The or each transverse slider <NUM> passes close to the free edge <NUM> of the substrate <NUM>.

At the beginning of the folding step, the edge <NUM> of the cover sheet <NUM> extends on the second clamping surface <NUM>.

When the or each transverse slider <NUM> is moved from the outer position (<FIG>) to the inner position (<FIG>), the edge <NUM> is pivoted around the folding line <NUM>.

In the inner position, the edge <NUM> extends longitudinally below the or each transverse slider <NUM>. Below means against the surface of the or each transverse slider <NUM> opposite the second clamping surface <NUM>.

The edge <NUM> extends in the cavity <NUM>. It extends between the free edge <NUM> of the substrate <NUM> and the or each transverse slider <NUM>.

During the displacement of the at least one longitudinal slider <NUM> from the retracted position to the extended position, the edge <NUM> is folded around the free edge <NUM> of the substrate. It is pressed against an inner surface <NUM> of the substrate <NUM>. The inner surface <NUM> is opposite the outer surface <NUM>.

The first mold section <NUM> and the second mold section <NUM> are then moved with respect one another to the open position, and the trim part <NUM> is removed.

Alternative embodiments can be considered for the apparatus / process described above.

The first clamping member <NUM> and / or the second clamping member <NUM> do not necessarily have a substantially closed contour. It can be open along a part of its contour.

The number of transverse sliders and the positions of the transverse sliders are chosen as a function of the portions of the free edge <NUM> of the substrate around which the edge <NUM> of the cover sheet must be folded.

The number of longitudinal sliders and the positions of the longitudinal sliders are chosen in consideration of the positions of the transverse sliders.

The apparatus / process described above has significant advantages.

Since the clamping frame is arranged for adjusting the clamping force by which the edge of the cover sheet is clamped between the first clamping member and the second clamping member in the clamping position, it is possible to control the displacement of the cover sheet when the main drive moves the first mold section and the second mold section with respect to one another to the molding position. This is particularly useful when the trim part comprises areas like curves or corners, where it is necessary to hold the cover sheet or to allow the edge to slide, depending on the properties of the material constituting the cover sheet.

When the clamping frame comprises an adjustable stopper, able to adjust the spacing between the first clamping surface and the second clamping surface in the clamping position, the clamping force can be easily adjusted. The apparatus can be readily adapted to cover sheets having various thicknesses or made from various materials.

When the first mold section comprises a main part defining a main area of the first surface area and at least one longitudinal slider movable with respect to the main part between an extended position and a retracted position, it becomes possible to laminate the cover sheet on the substrate and to fold the edge of the substrate in the same apparatus. In the state of the art, two different apparatus are frequently used to carry out these two operations. In the invention, the cover sheet is laminated on the substrate using both the main part and the at least one longitudinal slider. The at least one longitudinal slider is also used for folding the edge of the cover sheet. The apparatus is thus particularly compact.

When the second clamping member comprises at least one transverse slider, movable with respect to the second mold section between an outer position and an inner position, the apparatus is particularly compact. The transverse slider is integrated in the clamping frame.

Claim 1:
Apparatus for producing a trim panel (<NUM>) having at least a substrate (<NUM>) and a cover sheet (<NUM>) laminated to said substrate (<NUM>), the apparatus (<NUM>) comprising:
- a first mold section (<NUM>), with a first surface area (<NUM>) and a holding device (<NUM>) holding the substrate (<NUM>) on the first surface area (<NUM>);
- a second mold section (<NUM>), with a second surface area (<NUM>);
- a clamping frame (<NUM>), with a first clamping member (<NUM>), a second clamping member (<NUM>) and a clamping drive (<NUM>) moving the first clamping member (<NUM>) and the second clamping member (<NUM>) with respect to one another between a cover sheet clamping position and a cover sheet release position, an edge (<NUM>) of the cover sheet (<NUM>) being clamped between the first clamping member (<NUM>) and the second clamping member (<NUM>) in the clamping position, the edge (<NUM>) of the cover sheet (<NUM>) being free with respect to the first clamping member (<NUM>) and/or the second clamping member (<NUM>) in the release position, the cover sheet (<NUM>) extending between the first surface area (<NUM>) and the second surface area (<NUM>) in the clamping position;
- a main drive (<NUM>) moving the first mold section (<NUM>) and the second mold section (<NUM>) with respect to one another between a molding position and an open position, the first surface area (<NUM>) and the second surface area (<NUM>) being pressed against one another with the substrate (<NUM>) and the cover sheet (<NUM>) between them in the molding position, the first surface area (<NUM>) and the second surface area (<NUM>) being away from one another in the open position, wherein the main drive (<NUM>) moves the first mold section (<NUM>) with respect to the second mold section (<NUM>) longitudinally between the molding position and the open position,
the apparatus being characterized in that
the first mold section (<NUM>) comprises a main part (<NUM>) defining a main area (<NUM>) of the first surface area (<NUM>) and at least one longitudinal slider (<NUM>) movable with respect to the main part (<NUM>) between an extended position and a retracted position, the or each longitudinal slider (<NUM>) defining a first surface edge area (<NUM>) of the first surface area (<NUM>) in the extended position, and the or each longitudinal slider (<NUM>) being retracted longitudinally away from the first surface area (<NUM>) in the retracted position.