AUTOMOTIVE TRIM PART WITH INTEGRATED HEATING DEVICE

Abstract

Automotive trim part with an integrated heating device comprising at least an air permeable fibrous layer, a facing layer and a heating element, whereby the heating element is between the facing layer and the air permeable layer and materially connected to the adjacent layers, and further comprising means-for-connecting the heating element to a power supply, characterized in that at least part of the means-for-connecting and at least part of the material of the adjacent layer or layers are engulfed by a resin such that the means-for-connecting are at least partly encapsulated in the thermoplastic resin and materially connected to the adjacent layers.

Claims

1. Automotive trim part with integrated heating device comprising at least an air permeable fibrous layer, a facing layer and a heating element, whereby the heating element is between the facing layer and the air permeable layer and materially connected to the adjacent layers, and further comprising means-for-connecting the heating element to a power supply, characterized in that at least part of the means-for-connecting and at least part of the material of the adjacent layer or layers are engulfed by a resin such that the means-for-connecting are at least partly encapsulated in the resin and materially connected to the adjacent layers.

2. The trim part according to claim 1, whereby at least the permeable layer and the facing layer comprise a cut-out for locating the exit area for the means-for-connecting and whereby the cut-out area including the means-for-connecting is encapsulated by the resin such that the means-for-connecting and the material of the adjacent layers are materially connected.

3. The trim part according to claim 1, whereby the adjacent fibrous material is compressed such that a thinner area is obtained around the rim of the material opposite to the connector.

4. The trim part according to claim 1, whereby the resin is a thermoset or a thermoplastic resin, preferably the resin is a polymer or copolymer selected from the group consisting of polyolefin, like polyethylene (PE) or polypropylene (PP) or ethylene propylene diene monomer (EPDM) or ethylene-octene (EO), polyester or thermoplastic elastomer of polyester (TPE-E), polyamide (PA) or thermoplastic elastomer of polyamide (TPE-A), polyoxymethylene POM, acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC), Santoprene (TPV), styrene-butadiene copolymers (e.g. SBS), thermoplastic polyurethane (TPU), or a combination of these polymers.

5. The trim part according to claim 1, whereby the resin is a thermoplastic hotmelt based material, preferably the hotmelt material is based on a polymer or copolymer of one of polyester, like polyethylene terephthalate (PET), polyolefin, like polypropylene (PP) or polyethylene (PE), poly lactic acid (PLA), polyamide, like polyamide 6 (PA6) or polyamide 6,6 (PA6,6) or mixtures thereof.

6. The trim part according to claim 1, whereby the rein material further comprises fillers, preferably a fibrous filler, like glass fibers or carbon fibers, or an inert filler, like mica, carbon black or an inorganic filler like Barium Sulphate or Calcium carbonate or silica or a combination thereof.

7. The trim part according to claim 1, whereby the air permeable layer is one of a felt, for instance a fibrous mat, or textile material, for instance a spacer fabric or a carpet layer.

8. The trim part according to claim 1, whereby the trim part further comprises additional layers at least one of a tufted carpet, nonwoven carpet, decorative layer, knit layer, a foam layer, either slab foam or reaction injected foam, another fibrous layer, a thin nonwoven like a scrim or a closed or open film or an anti-skidding layer.

9. The trim part according to claim 8, whereby the cut-out is at least in one additional layer, preferably in all layers.

10. The trim part according to claim 1, whereby the facing layer is at least one of a tufted carpet, a nonwoven carpet, a textile fabric, like a knitted fabric, a faux-suede fabric or a woven fabric, a nonwoven fabric, a leather or a closed cell foamed layer, a film, a foil, a thermoplastic polyurethane layer, or a flocked surface layer or any combination of such layers.

11. The trim part according to claim 1, whereby at least a glue layer is used between the face layer and the heating element, and/or between the heating element and the air permeable fibrous layer.

12. The trim part according to claim 11, whereby at least the glue layer between the face layer and the heating element is a polyurethane based glue or a polyester based glue.

13. The trim part according to claim 1, wherein the heating element is a metal based or a carbon based resistance element.

14. The trim part according to claim 1, wherein the means-for-connecting comprises at least one of a cable, a plug, a connector, connecting points where wires are connected, a control device, and a sensor device.

15. Use of the trim part according to claim 1 as an interior part, like a floor mat, door trim, parcel shelf, visor part, hush panel or trim parts on or near the dash panel or underneath the dash panel, a trunk trim part or a front stowing area trim part or any trim part or cladding in the passenger compartment, or as an exterior trim part, for instance as a trim part around the engine.

16. A method of producing the automotive trim part with integrated heating device, comprising: providing at least an air permeable fibrous layer, a facing layer and a heating element, whereby the heating element is between the facing layer and the air permeable layer and materially connected to the adjacent layers, and further comprising means-for-connecting the heating element to a power supply, characterized in that at least part of the means-for-connecting and at least part of the material of the adjacent layer or layers are engulfed by a resin such that the means-for-connecting are at least partly encapsulated in the resin and materially connected to the adjacent layers; stacking at least a heating element, and a fibrous layer, whereby the fibrous layer already has a dedicated region and/or cut-out for a connecting zone; laminating the stacked layers together; connecting the means-for-connecting to the heating element before the lamination step, or after the lamination step; and characterized in that the method further comprises the step of local injection molding a resin to engulf at least part of the means-for-connecting and at least part of the material of the adjacent layer or layers by the resin such that the means-for-connecting are at least partly encapsulated in the thermoplastic resin and materially connected to the adjacent layers.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0087] FIG. 1 Example of a trim part in the form of a heated floor mat according to the invention.

[0088] FIG. 2 is a close up view of a connector integrated in the trim part according to the invention.

[0089] FIG. 3 shows the cross section A-A′ of FIG. 2.

[0090] FIG. 4 shows the cross section B-B′ of FIG. 2.

[0091] FIG. 5 shows different possible solution for integrating the means-for-connecting in the trim part according to the invention.

[0092] FIG. 1 shows an example of a trim part according to the invention. The trim part 1 is formed as a floor mat with an integrated heater in the form of a heating element 2 placed within the layers of the trim part. Such a carpet construction has at least a fibrous lower layer and a facing layer, for instance a carpet layer. The heater can be placed between these layers as a heating element alone or may be placed between the layers as a heating element on a carrier construction, for instance a nonwoven fleece, fabric or textile layer. The heating element might be connected to at least one of the adjacent layers to prevent the heating element from moving within the construction during production and/or use. Preferable all layers are laminated to each other thereby fixating the heater within the layers. Although the heater is shown on the drawing, in practice the heater is placed invisible between the layers. The heating element has at least two cables or wires coming from it, for the connection to the power supply. Other connecting wires might be available for instance for connecting to control units integrated in the heater within the trim part, or to be connected outside of the trim part. Wires might be grouped to have at least one connector or multiple connectors exiting the trim part, preferably the exit 4 is at the rim of the trim part, parallel to the horizontal boundaries of the trim part as shown in the example. However other direction might also be beneficial depending on the location and use of trim part within the vehicle.

[0093] In the trim part of the example formed as a floor mat, with F the front of the car is indicated, showing on the front side the flaps needed for the pedal area. In the example, the connector is located opposite the pedal area, directed to the car seats. This is advantageous as most car models have a connecting box under the seat to connect any electronic device to a power system of the car.

[0094] The power cables or wires coming from the heater 2 are connected to a power connector for the connection to a suitable power supply (not shown), normally a male-female connector is used whereby preferably the male connector is placed within the trim part. Depending on the connector used the actual connection of the cables and the connector might be inside the housing of the connector or before the housing of the connector. Preferably both the connector and the cable connection are encapsulated in the thermoplastic resin 3 forming a connecting zone or area, further protecting the electric contacts and the connection. This prevent the actual connection from getting in contact with water or condense water, therefor decreasing corrosion or oxidation of the connection. At the same time the connection is protected against tampering.

[0095] According to the invention the connector including at least part of the connected cables is encapsulated by an injection molded process such that the connector and cables are protected and at the same time attached to the surrounding layer or layers, in particularly to at least the fibrous layer. Optionally the area of the integrated connector 3 is created as a flap, separated from the main surface of the mat by a small cut or indent 5, enabling a higher degree of movement of the area. This will increase the handling of the floor mat during installing in, or taking out of the car, in particular plugging and unplugging of the floor mat is eased.

[0096] In one embodiment the carpet facing layer is placed on top of the fibrous layer after the local injection molding of the resin to encapsulate the connector and materially connect it to the adjacent layer or layers. In this case the carpet surface does not have a cut-out for the connector but is covering the connector such that it is no longer visible from the carpet surface.

[0097] FIG. 2 is showing an example of an encapsulated connector—in this case a socket or housing with an female connector 3—between the material of the adjacent layers. The socket is placed in a suitable cut-out in the final laminated trim part and connected to the wires of the heater (not shown). In the case shown the trim part 1 is made of 2 layers, a decorative face layer and a fibrous backing layer. The connector is encapsulated with a thermoplastic resin. The resin is at the same time materially connected to the material of the adjacent layers. In the description of FIGS. 3 and 4, the cross sections A-A′ and B-B′ will be further disclosed.

[0098] In FIGS. 3 and 4, the cross sections A-A′ and B-B′ are shown. In both figure a trim part with a carpet face layer 6 and an air permeable fibrous layer 7 forming a backing layer is shown. In between the two layer the heating element 2 is placed and all layers are laminated together.

[0099] The cut-out for the connector is preferable made before the lamination step, to prevent damage to the heater between the layers. The connector can be placed in the construction before the lamination step or is connected to the wire cables of the heating element after the lamination step.

[0100] As a heating element any type of flexible heater might be used. Preferably the heating element is flat, but pliable to form into the shape of the trim part, this might be curved or bended parts or truly 3 dimensional shaped trim parts. The heated element is either laid loosely on top of the lower fibrous layer or the heating element is embroidered or glued to a textile for instance a nonwoven fleece layer and laid on top of the lower fibrous layer. Preferably the heating element is facing the lower fibrous layer. The floor mat might be sewn around the rim with a ribbon to further enhance the floor mat. Other edging technics might be used to finalize the part. Optionally other heater systems known in the art, like foil printed version, might be used.

[0101] The connection point 8, where the heating element is connected to the means-for-connecting might be placed within the connector housing 3 or before the connector housing 3 within the cut-out space, such that the connection point is also encapsulated in thermoplastic resin 9. Preferably the rim 10 of the adjacent material layers is compressed such that the thermoplastic resin can be applied above and/or underneath the rim thereby strengthening the material connection between the resin and the layers.

[0102] The connector 3 is engulfed in a resin 9, whereby the resin is also attaching and/or penetrated into the adjacent areas of the layers surrounding the connector. The encapsulating resin is at least attached and connected to the fibrous backing layer, and into the fleece layer with the heating element as shown in zone 10. In addition the encapsulating resin might be attached or bonded to the connector 3 or other means-for-connecting, for instance the connecting point, within the connecting zone formed by the over-molded area 9.

[0103] The full face layer and/or optionally in case the face layer is formed of more than one layer at least the lower layer or layers of the face layer might be attached to the resin during the local injection molding of the encapsulation, or might be attached after the encapsulation and cover the connector such that it is not visible on the outer facing layer.

[0104] Other appliances might be attached to the floor mat like for instance means for mounting the floor mat to the main floor, local embossed logos etc.

[0105] The floor mat might have a rubber insert for instance for placement of the pedal foot. The heating wire may be adapted to go around the area of the rubber insert, if needed.

[0106] Optionally the floor mat might have a small cut next to the connector area such that this area can function as a flexible flap enabling an easy connection to the vehicle wiring system.

[0107] Although the floor mat is shown as a floor mat for the foot well areas of a vehicle the mat can also be used in other areas of the vehicle, for instance as a heating mat for the front or back trunk area, or for instance for the heating of an animal box placed within the car.

[0108] FIG. 5 is showing different possible solutions for integrating the means-for-connecting in the trim part according to the invention.

[0109] In all FIGS. 5A to 5D, schematically a trim part 1 is shown with the connecting zone 3 and the exit of the means-for-connecting 2. With a dotted line the overlap between the material of the adjacent layer and the penetration and/or engulfment of the resin material is shown. This overlapping area is the bonding zone between the resin and the adjacent layers, while all the space available in the connecting zone is taken by the resin accept for any area that belongs to a male or female connector plug.

[0110] In FIG. 5A the means for connecting are engulfed in a connecting zone, that is designed within the boundaries of the trim part. In FIG. 5B and 5C the connecting zone is partly or fully sticking out of the boundaries of the trim part. Although in the version of FIG. 5C the connecting zone is outside of the boundaries of the trim the overlapping zone is still available with the rim of the adjacent material and therefore forming a solid connection to the mat.

[0111] An alternative to the flap of FIG. 5C is a flap formed by the materials of the trim part, this has the advantage of a more flexible solution. The thus formed flap might be molded together with the lamination step of the part in a 3D shape, for instance out of the horizontal plane. The integration of the connecting zone might be as shown in FIG. 5D, or might be one of the solution as shown in FIGS. 5A to 5C.

[0112] Alternatively, the connecting zone is not situated at the rim of the trim part but might be located anywhere on the trim part, whereby the exit of the means for connecting is not necessary parallel to the horizontal boundaries of the trim part. For instance, as a connecting zone that is directed to a power supply underneath the back surface of trim part. Such trim parts might for instance be used preferably for areas which are not predominantly horizontal.