Patent Application
20070207292
The present invention generally relates to interior trim components, particularly, for the passenger compartment of a motor vehicle, and a method for producing interior trim components. More particularly, the present invention relates to interior trim components, such as motor vehicle instrument panels, door panels, bolsters, armrests, console lids, or other soft trim components, wherein the interior trim components give a preferred touch (i.e., soft touch feeling) to a portion where a passenger may touch and support localized portion of his or her weight.
It is known to provide motor vehicle interior trim components that are aesthetically and/or tactilely pleasing to the vehicle passengers. Such trim components commonly have cushioned soft-touch aesthetic features. In particular, interior vehicle door panels often have localized cushioned areas in the armrest. Such localized softness may be provided by a flexible foam or elastomeric pad of varying thickness typically mounted to a rigid structural substrate and surrounded by a relatively harder durometer cover sheet.
It is also known to form motor vehicle armrests by placing a nibbed back surface of a molded vinyl skin against a rigid structural substrate and clamping the vinyl skin to the underside of the substrate with a closure plate. However, known methods of manufacturing such armrests typically require a series of multiple and separate molding and assembly steps, which can add significant cost to each part produced. It would therefore be desirable to provide an improved motor vehicle armrests and method for manufacturing the same.
The present invention is directed towards an interior component for a motor vehicle comprising a substrate having a surface and flexible elements on the surface, and a cover covering at least a portion of the substrate and the flexible elements. The present invention is also directed towards a method for making an interior trim component.
Referring now to the drawings, there is illustrated in
Continuing with reference to
Referring now to
Although illustrated schematically in FIGS.3 and 4, it will be appreciated that the mold surfaces 26, 28, and 31 may be of any desired shape and contour. For example, the fourth mold surface 31 can be textured so as to create an aesthetically and tactilely pleasing outer surface 64 of the armrest assembly 10. The mold sections 22, 23, and 24 are preferably mounted to platens (not shown) of presses (not shown), such as vertical and horizontal molding presses, with sufficient tonnage to accomplish the method herein described.
It will be appreciated, that in accordance with each embodiment of the invention, a first step of the method of the invention includes providing a suitable mold assembly, and a plurality of voids or holes.
A second step of the method of this invention is illustrated generally at 34 in
A third step of the method of this invention is illustrated generally at 46 in
Preferably, the skin 52 becomes chemically bonded to the substrate 42 during the molding process to form the armrest assembly 10. However, such chemical bonding is not required. For example, features, such as recesses and protrusions, provided on the third mold surface 30 of the third mold section 23 may form corresponding ribs or pins 56 extending outwardly from the surface 44 of the substrate 42. Such recesses and protrusion may provide a mechanical bond with the skin 52 after the molten second material hardens to form the skin 52. Alternately, holes or recesses can be formed in the substrate (i.e., about the pins 56), such that the second material at least partially fills the recesses. The second material 50 thereby becomes bonded to the substrate 42 when the second material 50 hardens within the recesses.
The fourth mold section 24 is then moved away from the first mold section 20 and the armrest assembly 10 is removed from the second mold assembly 18. It will be appreciated that the method of the invention can be performed with satisfactory results in a shuttle-mold wherein the second, third and fourth mold sections 22, 23 and 24 move relative to a stationary first mold section 20. The method of the invention can also be performed with satisfactory results in a shuttle-mold wherein the first mold section 20 moves relative to stationary second, third and fourth mold sections 22, 23 and 24, or wherein all mold sections 20, 22, 23 and 24 move relative to one another.
Preferably, the armrest assembly 10 is manufactured using a two-shot molding process. The two-shot molding process may be accomplished by rotating the first mold section 20, such as in a rotational molding process. In such a rotational molding process, the substrate 42 is first injection molded in the first mold assembly 16 as described herein with reference to
The method of forming an armrest described herein, and the armrest formed thereby, is advantageous over prior art designs because the two-shot molding process eliminates the manual assembly required by the prior art methods. The method of the invention further improves quality, and eliminates the multiple components, such as structural members or substrates, foam inserts, outer covers or skins, closure plates, and adhesives or fasteners, of known armrest assemblies.
As shown in the drawings, the voids or holes 32 define a plurality of ribs or pins 56. The ribs or pins 56 are on, extend from, or are otherwise supported by the substrate 42, and into communication with the skin 52. The ribs or pins 56 can be arranged in any desired pattern in the armrest assembly 10. Preferably, the ribs or pins 56 are horizontally and/or laterally spaced apart, however the armrest assembly 10 may be manufactured having any desired pattern of ribs or pins 56.
It will also be appreciated that preformed ribs or pins 56a-56e can be on, embedded or otherwise molded into, or supported by the substrate 42a-42e, as described above. As stated above, the ribs or pins 56c-56d may be formed of a material that is more pliable than the substrate 42c-42d and molded into or supported by the substrate 42c-42d, or the ribs or pins 56a, 56b, 56e may be embedded in or otherwise supported by the substrate 42a, 42b, 42e with pliable holders, such as the pliable grommets or holders 57a, 57b, 57c shown.
A variety of rib or pin sizes, shapes, and locations can be provided so as to provide a desired feel to the outer surface 64 of the armrest assembly 10. For example, by varying the sizes, shapes, and locations of the ribs or pins 56, a manufacturer can control the relative softness of the armrest (e.g. how soft the armrest assembly 10 feels to a motor vehicle passenger). The pins can be substantially cylindrical, substantially cylindrical with a tapered distal end portion, or substantially cylindrical with a distal end portion having any other desired shape.
It will be appreciated that the interior trim component 10 can be attached to the vehicle door assembly by any desired method. For example, threaded fasteners can be inserted through an aperture in the interior trim component 10 and into the vehicle door assembly 14. Alternately, an underside or backside of the substrate 42 can include outwardly extending bosses (not shown) which define thermoplastic stakes. Such thermoplastic stakes can be extended through an aperture in the vehicle door assembly. It will be appreciated that the portion of the thermoplastic stake which extends through the vehicle door assembly may be melted and reformed, so as to mechanically bond the interior trim component 10 to the vehicle door assembly. The thermoplastic stake can be melted by any desired means, such as a heated aluminum platen (not shown).
The principle and mode of operation of this invention have been explained and illustrated in its preferred embodiment. However, it must be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope.
