Zero gap decoration integration by negative vacuum forming
A composite part is manufactured having at least two different appearances and/or feels in at least two surface. A localized deformation in the form of a groove in the skin is provided at each interface between the two surface zones and one of the surface zones is recessed in relation to the other zone. The recessed surface zone is displaced to bring the ridge of this zone flush with the corresponding ridge of the adjacent or contiguous surface zone. This confers on the skin its final form, and then duplicate molding on the internal face of the skin is performed to produce the composite part.
1 . A process for manufacturing a composite part having at least two different appearances and/or feels in the region of at least two directly adjacent or contiguous apparent surface zones;
providing a skin having an external face;
defining a groove in the skin to define an interstice between two adjacent surface zones whereby each surface zone includes an edge generally opposite the adjacent surface zones;
locating one of the surface zones set back from the other of the surface zones;
displacing the set back one of the surface zones such that it is flush with the other of the surface zones and the edges of each of the surface zone are in contact with one another; and
forming a first appearance in a first portion of the skin.
2 . The method of claim 1 wherein the steps of forming the first appearance occurs before the step of forming the groove.
3 . The method of claim 1 wherein the steps of forming the first appearance occurs after the step of forming the groove.
4 . The method of claim 1 further comprising the step of forming a second appearance in a second portion of the skin.
5 . The method of claim 1 wherein the steps of forming the first and second appearances occur simultaneously.
6 . The method of claim 4 wherein the steps of forming the first and second appearances occur sequentially.
7 . The method of claim 1 further comprising the steps of:
after the displacing step, molding a body of material to the skin on an internal face located opposite the external face to form a composite part; and
setting the body of material so as to provide a final shape to the composite part.
8 . The method of claim 7 wherein the displacing, molding and setting steps are performed in a single molding station.
9 . The method of claim 7 wherein the displacing, forming, molding and setting steps are performed in a single molding station.
10 . The method of claim 1 wherein the displacing and forming steps are performed in a single molding station.
11 . The method of claim 1 wherein the forming of the first appearance result in an area of demarcation being formed in the skin, the area of demarcation being located within the groove after the defining step.
12 . The method of claim 1 wherein the step of defining the groove includes thermoforming of the skin.
13 . The method of claim 12 wherein the step of thermoforming the skin is performed simultaneously with the step of forming the first appearance.
14 . The method of claim 12 wherein the step of thermoforming the skin is performed simultaneously with the steps of forming the first appearance and forming a second appearance in the skin.
15 . The method of claim 1 wherein the step of forming the first appearance is chose from the group of thermal surface treatments, thermo-mechanical surface treatments, surface impression, modification to surface condition in terms of roughness, grain, flatness or friction coefficient, and application of superficial layers or coatings.
16 . The method of claim 1 further comprising the step of arranging the edges of the adjacent surface zones, before the displacing step, in substantial alignment in the direction of displacing.
17 . The method of claim 1 wherein the defining step defines a groove with a depth greater than a wall thickness of the skin forming the groove and oriented at an incline relative to a line normal to the surface zones.
18 . The method of claim 1 wherein during the displacing step the portion of the skin defining the groove maintains its integrity.
19 . The method of claim 1 further comprising the step of forming a second appearance in portions of the skin located around the first portion.
20 . The method of claim 1 wherein the set back one of the surface zones is a central surface zone defined within the other of the surface zones and has a width substantially equal to a width defined between opposing edges of the other of the surface zones.
21 . The method of claim 20 wherein the forming of the first appearance is performed on the central surface zone.
22 . A composite part formed by the method of claim 1.