U.S. patent application number 09/748968 was filed with the patent office on 2001-10-18 for door trim panel assembly and method of making.
Invention is credited to Codd, Pamela L., Johnson, Stevie P., Stein, Arthur C., Whitehead, David W..
Application Number | 20010030444 09/748968 |
Document ID | / |
Family ID | 26869395 |
Filed Date | 2001-10-18 |
United States Patent
Application |
20010030444 |
Kind Code |
A1 |
Whitehead, David W. ; et
al. |
October 18, 2001 |
Door trim panel assembly and method of making
Abstract
A door trim panel assembly and method of making same for
attachment to structure of a vehicle includes a door trim panel and
a carrier formed from a plastic material attached to the door trim
panel and for attachment to the structure of the vehicle. The door
trim panel assembly also includes a seal integral with the carrier
for contacting the structure to seal the carrier to the
structure.
Inventors: |
Whitehead, David W.;
(Rochester Hills, MI) ; Stein, Arthur C.; (Grosse
Ile, MI) ; Codd, Pamela L.; (Rochester, MI) ;
Johnson, Stevie P.; (Shelby Township, MI) |
Correspondence
Address: |
Patrick M. Griffin
DELPHI TECHNOLOGIES, INC.
Mail Code: 480-414-420
P.O. Box 5052
Troy
MI
48007-5052
US
|
Family ID: |
26869395 |
Appl. No.: |
09/748968 |
Filed: |
December 27, 2000 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60173654 |
Dec 30, 1999 |
|
|
|
Current U.S.
Class: |
296/146.7 |
Current CPC
Class: |
B60J 5/0418 20130101;
B29C 37/0032 20130101; B29C 44/12 20130101; B60R 13/0243 20130101;
B29C 44/14 20130101; B60R 13/0206 20130101 |
Class at
Publication: |
296/146.7 |
International
Class: |
B60J 005/04 |
Claims
1. A door trim panel assembly for attachment to structure of a
vehicle comprising: a door trim panel; and a carrier formed from a
plastic material attached to said door trim panel and for
attachment to the structure of the vehicle; a seal integral with
said carrier for contacting the structure to seal said carrier to
the structure.
2. A door trim panel assembly as set forth in claim 1 wherein said
plastic material is comprises expanded polypropylene.
3. A door trim panel assembly as set forth in claim 1 wherein said
seal extends longitudinally and vertically around said carrier.
4. A door trim panel assembly as set forth in claim 1 wherein said
se al includes a groove extending therealong and inwardly.
5. A door trim panel assembly as set forth in claim 4 wherein said
seal includes a pair of laterally spaced projections, said groove
being disposed between said projections.
6. A door trim panel assembly as set forth in claim 4 wherein said
seal includes a sealing member disposed in said groove.
7. A door trim panel assembly as set forth in claim 1 wherein said
carrier has a first side and a second side.
8. A door trim panel assembly as set forth in claim 7 wherein said
seal extends from said second side.
9. A door trim panel assembly as set forth in claim 1 wherein said
seal comprises expanded polypropylene.
10. A door trim panel assembly as set forth in claim 1 wherein said
seal and said carrier are integral, unitary, and one-piece.
11. A method of making a door trim panel assembly for attachment to
structure of a vehicle, said method comprising the steps of:
placing a door trim panel into a cavity of a mold; filling the
cavity with a plastic material; and introducing steam into the mold
to expand the plastic material to form a carrier with an integral
seal and bond the carrier against the door trim panel to form a
single door trim panel assembly.
12. A method as set forth in claim 11 wherein said step of filling
comprises filling the cavity with a plurality of plastic beads.
13. A method as set forth in claim 12 wherein the plastic beads are
expanded polypropylene beads.
14. A method as set forth in claim 11 including the step of forming
the seal with a groove extending inwardly.
15. A method as set forth in claim 14 including the step of forming
the seal with a pair of laterally spaced projections with the
groove disposed between the projections.
16. A method as set forth in claim 11 including the step of forming
the door trim panel prior to said step of placing.
17. A method as set forth in claim 11 including the step of
pre-heating the door trim panel prior to said step of filling.
18. A method as set forth in claim 11 wherein said step of
introducing comprises introducing steam into a chamber behind the
cavity to expand the plastic beads.
19. A method as set forth in claim 11 including the step of cooling
the door trim panel assembly prior to said step of removing.
20. A method as set forth in claim 19 including the step of
disposing a sealing member in a groove of the seal.
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] The present invention claims the priority date of copending
U.S. Provisional Patent Application Ser. No. 60/173,654, filed Dec.
30, 1999.
TECHNICAL FIELD
[0002] The present invention relates generally to door trim panels
for vehicles and, more particularly, to a door trim panel assembly
for a vehicle.
BACKGROUND OF THE INVENTION
[0003] It is known to provide a door trim panel assembly for a
vehicle such as an automotive vehicle to present an aesthetically
pleasing appearance in an occupant compartment of the vehicle. The
door trim panel assembly includes a plurality of separate
components with each component having a specific function. The
components typically include a door trim panel, sound absorber,
water barrier, insert, armrest, map pocket closeout, and side
impact blocks. The components are assembled together and attached
to a door trim substrate by several different conventional
processes including adhesives, heat staking, sonic welding, and
fasteners.
[0004] The door trim substrate supports the components including
the door trim panel and is not thick enough to touch an inner panel
of the door since the materials for the substrate cannot be molded
that thick. As a result, the door trim panel assembly uses a flat
or pre-molded sheet material in conjunction with a bead of
pre-applied butyl caulk. A release paper is attached to the caulk
so that the parts can be stacked. The door trim panel assembly is
then mounted to the inner panel of the door for the vehicle by
removing the release paper and attaching with suitable means such
as fasteners.
[0005] Although the above door trim panel assembly has worked, it
is desirable to provide a seal on a backside or outer surface
thereof of the door trim panel assembly. It is also desirable to
provide a door trim panel assembly with an integrally molded seal
in an expanded polypropylene substrate that reduces parts, cost,
and assembly. It is further desirable to provide a door trim panel
assembly with a direct applied seal and an expanded polypropylene
substrate that reduces parts, cost, and assembly. Therefore, there
is a need in the art to provide an improved door trim panel
assembly for attachment to an inner panel of a door for a vehicle
that meets these desires.
SUMMARY OF THE INVENTION
[0006] It is, therefore, one object of the present invention to
provide a new door trim panel assembly for a vehicle.
[0007] It is another object of the present invention to provide a
door trim panel assembly that has an integrally molded seal into a
single component for attachment to an inner panel of a door for a
vehicle.
[0008] It is yet another object of the present invention to provide
a door trim panel assembly that has a direct applied seal into a
single component for attachment to an inner panel of a door for a
vehicle.
[0009] It is still another object of the present invention to
provide a door trim panel assembly that has fewer components and
cost.
[0010] To achieve the foregoing objects, the present invention is a
door trim panel assembly for attachment to structure of a vehicle
including a door trim panel and a carrier formed from a plastic
material attached to the door trim panel and for attachment to the
structure of the vehicle. The door trim panel assembly also
includes a seal integral with the carrier for contacting the
structure to seal the carrier to the structure.
[0011] In addition, the present invention is a method of making a
door trim panel assembly for attachment to structure of a vehicle.
The method includes the steps of placing a door trim panel into a
cavity of a mold and filling the cavity with a plastic material.
The method also includes the steps of introducing steam into the
mold to expand the plastic material to form a carrier with an
integral seal and bond the carrier against the door trim panel to
form a single door trim panel assembly.
[0012] One advantage of the present invention is that a new door
trim panel assembly is provided for a vehicle. Another advantage of
the present invention is that the door trim panel assembly has an
integrally molded seal and/or direct applied seal with an expanded
polypropylene carrier or substrate that eliminates traditional
watershields in doors for vehicles. Yet another advantage of the
present invention is that the door trim panel assembly reduces the
number of parts, labor, cost, and tooling for the same. Still
another advantage of the present invention is that the door trim
panel assembly improves serviceability and assembly plant handling
since butyl caulk and release paper are eliminated. A further
advantage of the present invention is that the door trim panel
assembly has enhanced performance and saves the cost of traditional
watershields, which increases the content on the door trim.
[0013] Other objects, features, and advantages of the present
invention will be readily appreciated, as the same becomes better
understood, after reading the subsequent description taken in
conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a perspective view of a door trim panel assembly,
according to the present invention, illustrated in operational
relationship with a vehicle.
[0015] FIG. 2 is a perspective rear view of the door trim panel
assembly of FIG. 1.
[0016] FIG. 3 is a fragmentary view of an integrally molded seal of
the door trim panel assembly of FIG. 1.
[0017] FIG. 4 is a fragmentary view of another embodiment,
according to the present invention, of the door trim panel assembly
of FIG. 1 illustrating a direct applied seal of the door trim panel
assembly.
[0018] FIG. 5 is a fragmentary elevational view of a mold for a
method, according to the present invention, of making the door trim
panel assembly of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] Referring to the drawings and in particular FIGS. 1 and 2,
one embodiment of a door trim panel assembly 10, according to the
present invention, is shown for mounting to structure such as a
door 12 of a vehicle 14. It should be appreciated that, in this
example, the door trim panel assembly 10 is mounted to an inner
panel 16 of the door 12. It should also be appreciated that the
door trim panel assembly 10 may be an assembly mounted to other
panels of the vehicle 14.
[0020] Referring to FIGS. 2 and 3, the door trim panel assembly 10
includes a door trim substrate or carrier 20 extending
longitudinally and vertically and having a generally rectangular
shape. The carrier 20 is made of a plastic material such as
polypropylene. Preferably, the carrier 20 is made of expanded
polypropylene (EPP). The carrier 20 is formed by a method,
according to the present invention, to be described. The carrier 20
has a first side 21 and an opposed second side 22. The second side
22 is attached to the inner panel 16 of the door 12 by suitable
means such as fasteners (not shown). It should be appreciated that
the carrier 20 may be molded thick enough to contact the inner
panel 16 of the door 12 when mounted to the door 12.
[0021] The door trim panel assembly 10 also includes at least one
seal 24 incorporated or integrated into the carrier 20. The seal 24
extends longitudinally and vertically around the carrier 20. The
seal 24 has a groove 26 extending therealong and inwardly to form a
pair of laterally spaced projections 28. The groove 26 allows the
projections 28 to compress and seal against the inner panel 16 of
the door 12. The seal 24 is made of a plastic material such as
polypropylene, preferably expanded polypropylene. The expanded
polypropylene is compliant enough at predetermined densities (2.8
to 3.5 pcf) to conform to the sheet metal of the inner panel 16 of
the door 12. The seal 24 is molded as part of the second side 22 of
the carrier 20 by the plastic material of the carrier 20. It should
be appreciated that the seal 24 and carrier 20 are integral,
unitary, and formed as one-piece. It should also be appreciated
that the seal 24 surrounds any openings 30,32 in the inner panel
16, as well as the entire perimeter of the inner panel 16 of the
door 12. It should be further appreciated that the seal 24 acts as
a water seal and water that enters the interface area between the
door trim panel assembly 10 and the inner panel 16 of the door 12
is channeled to drains (not shown) at the bottom of the door 12. It
should be still further appreciated that the seal 24 is illustrated
as uncompressed in FIG. 3.
[0022] The door trim panel assembly 10 includes a finished door
trim panel 34. The door trim panel 34 extends longitudinally and
vertically and is generally rectangular in shape. The carrier 20
conforms to the shape of the door trim panel 34 such that the
carrier 20 is disposed within the door trim panel 34. The door trim
panel 34 is made of a relatively rigid material such as hard
plastic, covered plastic, and covered cellulose based material or
composite of the like. The covering can be fabric, vinyl, cloth,
TPO, leather, carpet, or a combination thereof. The door trim panel
34 is formed by a suitable thermoplastic molding or forming process
such as injection molding, compression molding, thermoforming or
the like. Preferably, the door trim panel 34 is made of
polypropylene and formed by conventional injection molding
processes as is known in the art. The door trim panel 34 is
attached to the carrier 20 by molding the carrier 20 to the door
trim panel 34 by a method to be described. It should be appreciated
that the door trim panel 34 presents a class A surface as is known
in the art. It should also be appreciated that the door trim panel
34 is conventional and known in the art.
[0023] Referring to FIG. 4, another embodiment 110, according to
the present invention, of the door trim panel assembly 10 is shown.
Like parts of the door trim panel assembly 10 have like reference
numerals increased by one hundred (100). In this embodiment, the
door trim panel assembly 110 includes the carrier 120 having the
first side 121 and the second side 122 and the door trim panel 134.
The door trim panel assembly 110 also includes the seal 124 having
at least one seal retainer 136 incorporated or integrated into the
carrier 120. The seal retainer 136 extends longitudinally and
vertically around the carrier 120. The seal retainer 136 has a
groove 138 extending therealong and inwardly to form a pair of
laterally spaced projections 140. The seal 124 also includes a
directly applied sealing member 142 disposed in the groove 138 to
compress and seal against the inner panel 16 of the door 12. The
seal retainer 136 is made of a plastic material such as
polypropylene. The sealing member 142 is made of a suitable
material such as butyl rubber, one component urethane, two
component urethane, no tack foamed hot melt, low tack foamed hot
melt, high tack foamed hot melt, silicone or the like. The seal
retainer 136 is molded as part of the second side 122 of the
carrier 120 by the plastic material of the carrier 120. It should
be appreciated that the seal retainer 136 and carrier 120 are
integral, unitary, and formed as one-piece. It should also be
appreciated that the sealing member 142 is illustrated as
uncompressed in FIG. 4.
[0024] A method, according to the present invention, of making the
door trim panel assembly 10 is disclosed. A mold, generally
indicated at 50, includes a first half mold 52 and a second half
mold 54. The first and second half molds 52 and 54 are generally
hollow to form a chamber 56. The first and second half molds 52 and
54 have an inlet 58 for allowing a fluid such as steam to enter the
chamber 56 of the first and second half molds 52 and 54. The first
and second half molds 52 and 54 each include a mold cavity 60 for
forming the carrier 20. The first half mold 52 includes at least
one, preferably a plurality of fill inlets 62 extending into the
mold cavity 60 to allow fill guns (not shown) to fill the mold
cavity 60 with the plastic material for the carrier 20. It should
be appreciated that the mold 50 is conventional and known in the
art.
[0025] The method, according to the present invention, includes the
step of forming the door trim panel 34,134 by conventional
processes such as injection molding or other suitable thermoplastic
molding or forming process (i.e., compression molding,
thermoforming, etc.). The door trim panel 34,134 is preferably
designed with at least one, preferably a plurality of "undercut"
members to facilitate mechanical bonding of the carrier 20,120. The
method may include the step of preheating the door trim panel
34,134 using an infrared oven (not shown) or the like. Preferably,
the door trim panel 34,134 would be demolded from the injection
molder (not shown) at higher-than-ambient temperature and placed
into the mold cavity 60 of the mold 50.
[0026] The method includes the step of placing the door trim panel
34,134 into the mold cavity 60 of the mold 50. The method includes
the step of closing the mold 50 and filling the mold cavity 60 with
the plastic material for the carrier 20,120. In the preferred
embodiment, the plastic material is expanded polypropylene. As
such, the mold cavity 60 is filled with beads of expanded
polypropylene, which enter the mold 50 via the fill inlets 62.
Next, the method includes the step of introducing steam into the
mold 50 via the inlets 58 to expand the plastic material to form
the carrier 20, 120 and seal 24 or seal retainer 136 and bonding
the plastic material to the door trim panel 34,134 to form a single
door trim panel assembly 10,110. In particular, steam enters the
chambers 56 of the first and second half molds 52 and 54 through
the inlets 58. The beads of expanded polypropylene are fused
together with mechanical and thermoplastic bonding occurring to the
door trim panel 34,134. It should be appreciated that the steam
enters through openings in the door trim panel 34,134 and through
openings in the first half mold 52 to expand the beads of
polypropylene.
[0027] The method may include the step of cooling the mold 50 by
spraying a coolant such as water through nozzles (not shown) onto
the backside of the mold cavity 60 of the mold 50. Once the door
trim panel assembly 10,110 is cooled or after a suitable time for
fusion and cooling, the method includes the step of opening the
mold 50 and removing or demolding the door trim panel assembly
10,110 from the mold 50.
[0028] For the door trim panel assembly 110, the method includes
the step of placing the door trim panel assembly 110 on a holding
fixture (not shown) and applying the sealing member 142 to the seal
retainer 136 by an apparatus such as a robot (not shown) and
disposing the sealing member 142 in the groove 138. Finally, the
method includes attaching the door trim panel assembly 10,110 to
the inner panel 16 of the door 12 by suitable means such as
fasteners, adhesives, heat staking, sonic welding or the like or
the natural adhesive characteristics of the seal material itself
(foamed hot melts) to hold the seal 24,124 tightly against the
inner panel 16 of the door 12. It should be appreciated that the
seal 24 or applied sealing member 142 in combination with the
expanded polypropylene (EPP) material or surface itself seals water
and vapor from entering the vehicle 14 through the door 12.
[0029] The present invention has been described in an illustrative
manner. It is to be understood that the terminology, which has been
used, is intended to be in the nature of words of description
rather than of limitation.
[0030] Many modifications and variations of the present invention
are possible in light of the above teachings. Therefore, within the
scope of the appended claims, the present invention may be
practiced other than as specifically described.
* * * * *