Patent Description:
Document <CIT> discloses an interior trim part for a vehicle, the interior trim part having a structural part and the structural part comprising:.

The base protrusion comprises a flange and substantially triangular ribs integral with the flange and the second base portion. The ribs are spaced from each other and connected to the base portion external face of the second base portion. So, the foam layer must extend between the ribs and the foam layer must also cover the ribs. As gas release may occur when the foam layer is high, only quite small ribs can avoid problems during foaming. Moreover, marks may appear on the cover at each rib. Furthermore, when an occupant touches the interior trim part the feel is uneven. So, such an embodiment is not fully satisfying.

The purpose of the present disclosure is to enable having less restrained interior trim part shapes with satisfying appearance and touch feeling.

According to the present disclosure, the interior trim part has a structural part and the structural part comprises:.

As the interior trim part has first wall cavities extending through the first wall of the chute channel along the protrusion demolding direction which is not parallel with the chute demolding direction, the base protrusion may protrude with respect to the second base portion from more than few millimeters while avoiding huge thickness of material everywhere in the structural part. Therefore, the molding time is not substantially increased and the appearance of the interior trim part is satisfying.

According to another feature in accordance with the present disclosure, preferably the chute channel internal face includes a first wall edge surface extending from the first end over a first wall edge distance being not lower than <NUM> millimeters along the chute demolding direction, and the first wall edge surface is deprived of cavities.

Thus, the risk of tear of the airbag by contact against the chute channel internal face, near the first end, during deployment is reduced.

More preferably, the first wall edge surface extends from the first end, at least <NUM> millimeters in the chute demolding direction.

According to another feature in accordance with the present disclosure, preferably the first wall cavity bottom is distant from the base portion external face by a cavity bottom thickness which is between <NUM> and <NUM> millimeters.

Therefore, increase of the cycle time for manufacturing the interior trim part is avoided.

In advantageous embodiments, the interior trim part preferably further has one or more of the following features:.

The present disclosure also relates to an assembly comprising the above mentioned interior trim part further and an airbag module adapted for being expanded through the expansion passage.

The present disclosure also relates to process for producing the interior trim part comprising:.

The process preferably also comprises providing the cover and producing the foam layer by foaming between the base portion and the cover.

Other features and advantages of the present disclosure will appear in the following detailed description, with reference to the appended drawings in which:.

<FIG> and <FIG> illustrate an assembly <NUM> comprising an interior trim part <NUM> and an airbag module <NUM>. The interior trim part comprises a structural part <NUM>, a cover <NUM> and a foam layer <NUM>.

As shown in <FIG>, the structural part <NUM> is a single part including a chute channel portion <NUM>, a base portion <NUM> and a reinforcing portion <NUM>.

The chute channel portion <NUM> has a substantially tubular shape extending along a chute demolding direction Z between a first end <NUM> and a second end <NUM>. The chute channel portion <NUM> has a substantially rectangular cross-section. The chute channel comprises a first wall <NUM>, a second wall <NUM>, a left-side wall <NUM> and a right-side wall <NUM>. The left-side wall <NUM> and the right-side wall <NUM> extends between the first wall <NUM> and the second wall <NUM>. The chute channel portion <NUM> has a chute channel internal face 10a and a chute channel external face 10b. The chute channel <NUM> has an expansion passage <NUM>. The expansion passage <NUM> extends between the first end <NUM> and the second end <NUM> along the chute demolding direction Z and the expansion passage <NUM> is delimited by the first wall <NUM>, the second wall <NUM>, the left-side wall <NUM> and the right-side wall <NUM> perpendicularly to the chute demolding direction Z.

In the embodiments shown in the figures, the interior trim part <NUM> is a dashboard, the first wall <NUM> is a front wall, the second wall <NUM> is a back wall, the first end <NUM> is an upper end and the second end <NUM> is a lower end. Even if, the interior trim part is preferably a dashboard or at least a dashboard portion, the interior trim part can also be for example a door panel or a roof panel.

The base portion <NUM> is integral with the chute channel portion <NUM>. The base portion <NUM> has a base portion internal face 20a and a base portion external face 20b. The base portion <NUM> has a base portion thickness between the base portion internal face 20a and the base portion external face 20b. The base portion thickness is substantially constant and preferably between <NUM> millimeters and <NUM> millimeters. Preferably, the base portion <NUM> has no hollow in order to avoid foam leakage during foaming, no recess and the base portion external face 20b is substantially smooth.

The base portion <NUM> comprises a first base portion <NUM>, a base protrusion <NUM> and a second base portion <NUM>.

The first base portion <NUM> is a base top, is at the top of the base portion <NUM> and is substantially horizontal. The first base portion is substantially flat, but in a variant the first base portion could be slightly curved. The base portion internal face 20a of the first base portion <NUM> is connected to the first end <NUM> of the chute channel portion <NUM>. The first base portion <NUM> comprises a flap <NUM> which closes the first end <NUM> of the expansion passage <NUM>. The flap <NUM> is preferably at least partially surrounded by a weakness line in order to open during the airbag expansion. The flap is substantially rectangular. In the illustrated embodiment, the weakness line has a U-shape extending along <NUM> of the four sides of the flap <NUM>, the flap <NUM> being intended to rotate along the fourth side to open, as well known. In a variant, two flaps with a H-shape weakness line (or more than two flaps, for instance four flaps with cross shape weakness line) can be substituted for the U shape single flap <NUM> of the illustrated embodiment.

The second base portion <NUM> is a base front, is substantially vertical and is intended to face a vehicle occupant. The second base portion <NUM> is substantially angled between <NUM> and <NUM> degrees with respect to the first base portion. The second base portion <NUM> is substantially parallel to the second wall <NUM>. The base protrusion <NUM> extends between the first base portion <NUM> and the second base portion <NUM>. The base protrusion <NUM> is substantially curved. In the illustrated embodiment, the curvature is substantially constant. In a variant, the base protrusion can have in cross section a broken line shape, the protrusion comprising several successive substantially flat planes connected to each other. Regarding the base portion external face 20b, the base protrusion <NUM> protrudes from the second base portion <NUM>. Regarding the base portion internal face 20a, the base protrusion <NUM> defines a recess <NUM>.

The second base portion <NUM> is substantially parallel to the first wall <NUM> and the second wall <NUM>. The first wall <NUM> is closest to the base protrusion <NUM> than the second wall <NUM>.

The reinforcing portion <NUM> is integral with the chute channel portion <NUM>. The reinforcing portion <NUM> is also integral with the base portion <NUM>. The reinforcing portion <NUM> is connected to the base portion internal face 20a.

The reinforcing portion <NUM> defines a plurality of cavities <NUM>. In the embodiment shown in <FIG> and <FIG>, the cavities <NUM> extends in a protrusion demolding direction D. The reinforcing portion <NUM> comprises ribs <NUM> connected to the chute channel portion <NUM> and to the base portion <NUM>.

The cavities <NUM> include first wall cavities <NUM>. The first wall cavities <NUM> extend through the first wall <NUM>. Each of the first wall cavities <NUM> extends in the protrusion demolding direction D between a first wall cavity bottom 34a and a wall cavity free end 34b. The first wall cavity free end 34b of the first wall cavities <NUM> are at the chute channel internal face 10a. In the embodiments shown, the first wall cavity bottom 34a extend in part in the recess <NUM> at the chute channel internal surface 20a.

The ribs <NUM> comprise first wall ribs <NUM>. The first wall ribs <NUM> extend between first wall cavities <NUM>. The first wall ribs <NUM> extend along the protrusion demolding direction D between a base portion end 36a and a first wall end 36b. The base portion end 36a of the first wall ribs <NUM> is connected to the base portion internal face 20a. The first wall end 36b of the first wall ribs <NUM> is at the chute channel internal face 10a. At the first wall end 36b, the first wall ribs <NUM> defines at least part of the first wall <NUM>.

The ribs <NUM> also comprise ribs extending between the second wall <NUM> and base portion internal face 20a which are optional and, in the present embodiment, extend along the protrusion demolding direction D. In a variant, the structural part could also comprise ribs <NUM> extending between the base and portion <NUM> and the left side wall <NUM> as well as ribs <NUM> extending between the base and portion <NUM> and the right side wall <NUM>, so that the ribs <NUM> would surround the chute channel portion <NUM>.

The first wall cavity bottom 34a is distant from the base portion external face 20a by a cavity bottom thickness E. The cavity bottom thickness E is substantially equal to the base portion thickness. The cavity bottom thickness E is between <NUM> and <NUM> millimeters.

The first wall cavity free end 34b is distant from the base portion internal face 20a. A first wall edge surface 11b extends between the base portion internal face 20a and the first wall cavity free end 34b. Therefore, the first wall edge surface 11b is deprived of cavities and smooth. Along the chute demolding direction Z, the first wall edge surface 11b extend over a first wall edge distance d which is between <NUM> millimeters and <NUM> millimeters, preferably between <NUM> millimeters and <NUM> millimeters.

Perpendicularly to the protrusion demolding direction D, the first wall ribs <NUM> have a first wall rib thickness T. The first wall rib thickness T is preferably between <NUM> and <NUM> millimeters, more preferably between <NUM> and <NUM> millimeters.

Perpendicularly to the protrusion demolding direction D, the distance between two successive first wall ribs <NUM>, i.e. the width w of the first wall cavities <NUM> is preferably between <NUM> millimeters and <NUM> millimeters.

Regarding the base portion external face 20b, the base protrusion <NUM> protrudes from the second base portion <NUM> over a protrusion distance P along a direction perpendicular to the chute demolding direction Z which is preferably between <NUM> millimeters and <NUM> millimeters.

The protrusion demolding direction D defines a deviation angle α with respect to the chute demolding direction Z. The deviation angle α is non null, preferably between <NUM> and <NUM> degrees.

The airbag module <NUM> comprises an airbag and an inflator intended to inflate the airbag, so that the airbag expands. The airbag module <NUM> is arranged near or in the expansion passage <NUM>, so that the airbag may expand through the expansion passage <NUM>, open the flap <NUM> and expand in the passenger compartment. The airbag module <NUM> is supported by the chute channel portion <NUM> and/or by a cross bar.

The foam layer <NUM> is between the base portion <NUM> and the cover <NUM>. The foam layer <NUM> has a substantially constant thickness. The whole foam layer <NUM> is supported by the base portion <NUM>. The foam layer <NUM> is preferably achieved by foaming between the base portion <NUM> and the cover <NUM>.

In the embodiment shown in <FIG>, the first wall ribs <NUM> are plane, parallel and separate. The first wall ribs <NUM> have a substantially constant thickness.

<FIG> show a mold <NUM> for molding the structural part <NUM>. The mold comprises a first mold part <NUM>, a second mold part <NUM> and a movable mold part <NUM>. The second mold part <NUM> is movable with respect to the first mold part <NUM> along the protruding demolding direction D between a closing position shown in <FIG> and <FIG> and an opening position shown in <FIG>. The movable mold part <NUM> is movable with respect to the first mold part <NUM> along the chute demolding direction Z between a forward position shown in <FIG> and a backward position shown in <FIG> and <FIG>.

In <FIG>, the second mold part <NUM> is in the closing position and the movable mold part <NUM> is in the forward position. The first mold part <NUM>, the second mold part <NUM> and the movable mold part <NUM> define a molding cavity <NUM>. Thermoplastic material is injected in the molding cavity <NUM>, so that the structural part <NUM> is molded, as shown in <FIG>. Then, the movable part <NUM> is moved from the forward position to the backward position along the chute demolding direction Z, as represented by arrow <NUM>. Afterwards, as shown in <FIG>, the second mold part <NUM> is moved from the closing position to the opening position along the protrusion demolding direction D, as represented by arrow <NUM>.

<FIG> shows a second embodiment which differs from the first embodiment shown in <FIG> and <FIG> in that ribs <NUM> perpendicularly crossing one another and defining cavities <NUM> are substituted for separate and parallel ribs. In particular, the ribs <NUM> comprise first wall ribs <NUM> defining first wall cavities <NUM>.

In the embodiment shown in <FIG>, the first wall ribs <NUM> define a pattern with (substantially) squares having sides between <NUM> millimeters and <NUM> millimeters. In the embodiment shown in <FIG>, the first wall ribs <NUM> have a first wall rib thickness T which can be lower than in the embodiment shown in <FIG> and <FIG>, preferably between <NUM> millimeters and <NUM> millimeters, due to the pattern (with crossing ribs).

Other patterns for the ribs <NUM> can be contemplated, in particular ribs having not constant thickness and defining rounded cavities <NUM>.

Claim 1:
An interior trim part (<NUM>) for a vehicle, the interior trim part having a structural part (<NUM>), the structural part (<NUM>) comprising:
- a chute channel portion (<NUM>) having a substantially tubular shape extending along a chute demolding direction (Z) between a first end (<NUM>) and a second end (<NUM>), the chute channel portion (<NUM>) comprising a first wall (<NUM>), a second wall (<NUM>) and two side walls (<NUM>, <NUM>) extending between the first wall (<NUM>) and the second wall (<NUM>), the chute channel portion (<NUM>) has a chute channel internal face (10a), the chute channel internal face (10a) delimits an expansion passage (<NUM>) intended to guide an expansion of an airbag,
- a base portion (<NUM>) having a base portion internal face (20a) and a base portion external face (20b), the base portion (<NUM>) comprises a first base portion (<NUM>), a base protrusion (<NUM>) and a second base portion (<NUM>), the base portion internal face (20a) of the first base portion (<NUM>) is connected to the first end (<NUM>) of the chute channel portion (<NUM>), the base protrusion (<NUM>) extends between the first base portion (<NUM>) and the second base portion (<NUM>), the external surface (20b) of the base protrusion (<NUM>) protrudes with respect to the external surface (20b) of the second base portion (<NUM>) and the base portion internal face (20a) of the base protrusion (<NUM>) defines a recess (<NUM>), and
- a reinforcing portion (<NUM>) integral with the chute channel portion (<NUM>) and the base portion (<NUM>), the reinforcing portion (<NUM>) is connected to the base portion internal face (20a), the reinforcing portion (<NUM>) defines a plurality of cavities (<NUM>),
the interior trim part is characterized in that :
- the base portion (<NUM>) is integral with the chute channel portion (<NUM>), and
- the cavities (<NUM>) include first wall cavities (<NUM>) extending through the first wall (<NUM>), each of the first wall cavities (<NUM>) extends in a protrusion demolding direction (D) between a first wall cavity bottom (34a) and a first wall cavity free end (34b), the first wall cavity bottom (34a) being at the base portion internal surface (20a), the first wall cavity free end (34b) being at the chute channel internal face (10a), the protrusion demolding direction (D) defining a deviation angle (α) with respect to the chute demolding direction (Z), the deviation angle (α) being non null.