The present application relates generally to the field of molded articles or components having a substrate, a coverstock, and a decorative element coupled to the coverstock. More particularly, the present invention relates to vehicle trim panels that include a molded substrate, a coverstock, and a decorative element coupled to the coverstock with a pressure sensitive adhesive.
It is generally known to provide a laminated panel that includes a cover layer bonded to a rigid substrate that has been softened by heat. Such known cover layers comprise decorative elements that are attached by a projection extending from the decorative element through a hole in the substrate and then held in place by heat staking or a fastener. However, such known methods require additional labor and/or fixturing during assembling, may incur craftsmanship issues (e.g., gaps between the decorative element and the trim panel, noise during consumer use, etc.), or be susceptible to breakage.
Accordingly, it would be advantageous to provide a molded article having a coverstock with one or more decorative elements coupled to the coverstock by a pressure sensitive adhesive. It would also be advantageous to provide a trim panel with the decorative element located within a recess formed in the coverstock and/or substrate. To provide an inexpensive, reliable, and widely adaptable in-molded decorative element that avoids the above-referenced and other problems would represent a significant advance in the art.
According to one embodiment, the invention is directed to a molded article, such as a door trim panel, for a vehicle interior comprising a coverstock configured to provide at least a portion of an A-side of the molded article; a decorative element coupled to the coverstock by an adhesive; and a substrate molded behind the coverstock and configured to provide structural support to the coverstock. The decorative element may be injection molded. The adhesive may comprise a pressure sensitive adhesive. The coverstock and substrate may comprise a recess for the decorative element to be located at least partially within.
According to another embodiment, the invention is directed to a method of making a molded article for a vehicle interior comprising providing a coverstock and a decorative element; applying the decorative element to the coverstock with an adhesive; positioning the coverstock and decorative element in a mold; and introducing plastic resin to the mold and forming a substrate. The adhesive may comprise a pressure sensitive adhesive such that the step of introducing plastic resin comprises setting the pressure sensitive adhesive to bond the decorative element to the coverstock. The method may further comprise forming a pocket in the coverstock and substrate around the decorative element.
Coverstock 18 may be made from any of a variety of materials and compositions including fabric (woven, non-woven, etc.) textile, natural, polymer, or the like or combinations thereof; and may have multiple layers (e.g., foam, outer, inner, scrim, etc.).
Decorative element 22 is disposed or located in a recess 24 (e.g., pocket, indent, indentation, etc.), and may extend beyond or outside recess 24 relative to the surface of coverstock 18. For example,
According to a preferred embodiment, decorative element 22 comprises flexible and/or compressible materials. According to another embodiment, decorative element 22 comprises an injection molded plastic material. According to yet another embodiment, decorative element 22 comprises a dome coat urethane. According to various other embodiments, the decorative element may be any of a variety of flexible or rigid members intended for disposition on the A-surface of the coverstock.
According to a preferred embodiment, decorative element 22 is applied to coverstock 18 before being placed in the molding tool for molding of the substrate 20. Mold 28 closes (or partially closes) around coverstock 18 (e.g., by moving the mold sections toward each other or one of the sections toward the other section) so that a cavity or gap is provided between core 32 and cavity 30. The placement and orientation of coverstock 18 generally follows the contours of the mold sections.
Referring to
After plastic resin forms substrate 20, the trim panel 16 can undergo any of a variety of finishing operations (e.g., removing any portions of coverstock not attached to substrate (e.g., the portion or strip containing apertures), wrapping around and coupling to the B surface of substrate (e.g., by fasteners, adhesives, welding, heat staking, or the like).
It is to be understood that the invention is not limited to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments or being practiced or carried out in various ways. The molded article described in this disclosure may be employed in a variety of applications, and is generally applicable with any application where it would be beneficial to provide a molded article having two or more areas or portions of different decorative elements that are registered to specific areas of the panel. When the molded article is a trim panel for use in a vehicle, it is suitable for use in an interior passenger compartment of a vehicle, and may find utility in the form of door panels, dashboards, instrument panels, consoles, sidewall trim, overhead liners, sun visors, or other vehicle components or portions thereof. While the disclosed embodiments may be described as a vehicle trim panel, such as a door panel, the features of the disclosed embodiments are equally applicable with other applications such as other panels, molded articles and components and other office, home, or educational, industrial, commercial, or consumer products which employ localized areas or regions of various or different ornamental appearances. It is also to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting. For example, the terms “substrate,” “coverstock,” and “decorative elements” are intended to be broad terms and not terms of limitation. These components may be used with any of a variety of products or arrangements and are not intended to be limited to use with automotive applications.
In general, the component or molded article described in this disclosure is a molded article having a substrate coupled to a coverstock that has a decorative element coupled to the coverstock. In one embodiment, the molded article is configured as a trim panel for use in a vehicle (e.g., automobiles such as cars, vans, sport utility vehicles, trucks, buses, airplanes, boats, etc.). Providing a trim panel with a coverstock having a decorative element is intended to allow for a wide variety of decorative element possibilities for trim panels on a wide variety of vehicles (e.g., economy, luxury, etc.) in view of manufacturing efficiencies associated with the production of the coverstock and molding the substrate against the coverstock.
Also, the particular materials used to construct the exemplary embodiments are also illustrative For example, injection molded polypropylene is the preferred method and material for making the substrate, but other materials can be used, including other thermoplastic resins such as polyethylene, acrylonitrile butadiene styrene (“ABS”), polyurethane nylon, any of a variety of homopolymer plastics, copolymer plastics, plastics with special additives, filled plastics, etc. Also, other molding operations may be used to form these components, such as injection compression molding, etc. The coverstock is preferably made from vinyl, but can be made from any of a variety of materials and compositions including fabric, cloth, natural material (e.g., leather, etc.), textile (woven, non-woven, knit, etc.), polymer (e.g., thermoplastic elastomer polyolefin (TPO), or materials formed by reaction injection molding (RIM), etc.), elastomer, or the like or combinations thereof; and may have multiple layers (e.g., outer, inner, scrim, etc.).
It is important to note that the construction and arrangement of the elements of the vehicle trim panel as shown in the preferred and other exemplary embodiments is illustrative only. The method may be used for manufacture of any of a variety of trim panels having multiple decorative elements, which may be provided as any of a variety of shapes or configurations on the trim panel. Although only a few embodiments of the present inventions have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the claims. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the [position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. It should be noted that the elements and/or components of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures and combinations. Accordingly, all such modifications are intended to be included within the scope of the present invention as defined in the appended claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. In the claims, any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the exemplary embodiments without departing from the spirit of the. present inventions as expressed in the appended claims.
This Application claims the benefit of U.S. Provisional Application No. 60/752,834, filed Dec. 22, 2005, the content of which is incorporated herein by reference in its entirety.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/US06/48007 | 12/18/2006 | WO | 00 | 10/16/2008 |
Number | Date | Country | |
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60752834 | Dec 2005 | US |