U.S. patent application number 11/162010 was filed with the patent office on 2005-12-15 for trim panel assembly having an integrated door bumper and method of manufacture.
This patent application is currently assigned to LEAR CORPORATION. Invention is credited to Cowelchuk, Glenn A., Reed, Randy S., Schoemann, Michael P., Youngs, John D..
Application Number | 20050275134 11/162010 |
Document ID | / |
Family ID | 34991865 |
Filed Date | 2005-12-15 |
United States Patent
Application |
20050275134 |
Kind Code |
A1 |
Cowelchuk, Glenn A. ; et
al. |
December 15, 2005 |
TRIM PANEL ASSEMBLY HAVING AN INTEGRATED DOOR BUMPER AND METHOD OF
MANUFACTURE
Abstract
In at least certain embodiments, the present invention relates
to a trim panel assembly and a method of making the same. The trim
panel assembly comprises a housing having a perimeter portion
defining an opening. The housing comprises a housing panel and a
housing skin covering at least a portion of the housing panel. The
trim panel assembly further comprises a door moveable between a
first position wherein the door closes the opening to a second
position wherein the door provides access to the opening. The door
comprises a door panel and a door skin covering at least a portion
of the door panel. The trim panel assembly further comprises a
bumper disposed between the housing and the door. The bumper and at
least one of the skins are made during the same injection molding
step.
Inventors: |
Cowelchuk, Glenn A.;
(Chesterfield Twp., MI) ; Reed, Randy S.; (Fair
Haven, MI) ; Schoemann, Michael P.; (Waterford,
MI) ; Youngs, John D.; (Southgate, MI) |
Correspondence
Address: |
BROOKS KUSHMAN P.C. / LEAR CORPORATION
1000 TOWN CENTER
TWENTY-SECOND FLOOR
SOUTHFIELD
MI
48075-1238
US
|
Assignee: |
LEAR CORPORATION
21557 Telegraph Road
Southfield
MI
|
Family ID: |
34991865 |
Appl. No.: |
11/162010 |
Filed: |
August 25, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11162010 |
Aug 25, 2005 |
|
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10852276 |
May 24, 2004 |
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6945583 |
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Current U.S.
Class: |
264/239 ;
280/728.3 |
Current CPC
Class: |
B60R 7/06 20130101 |
Class at
Publication: |
264/239 ;
280/728.3 |
International
Class: |
B27N 003/08; B60R
021/16 |
Claims
What is claimed is:
1. A method for making trim panel assembly, said method comprising:
providing a housing comprising a housing panel having a perimeter
portion defining an opening, and a housing skin covering at least a
portion of the housing panel; providing a door connectable with the
housing which is moveable between a first position wherein the door
closes the opening to a second position wherein the door provides
access to the opening, the door comprising a door panel and a door
skin covering at least a portion of the door panel; and providing a
bumper disposed between the housing and the door, where the bumper
and at least one of the skins are made during the same injection
molding step.
2. The panel assembly of claim 1 wherein the bumper is located on
the door or the housing perimeter portion.
3. The trim panel assembly of claim 1 wherein an extension portion
extends between and connects the bumper and the at least one skin,
the extension portion and the bumper being made of the same
material.
4. The trim panel assembly of claim 3 wherein the extension portion
extends through the door panel.
5. The trim panel assembly of claim 3 wherein the extension portion
extends around an edge of the door panel.
6. The trim panel assembly of claim 2 wherein an extension portion
extends between and connects the bumper and the housing skin.
7. The instrument panel of claim 6 wherein the extension portion
has at least a portion extending through the housing panel.
8. The trim panel assembly of claim 6 wherein the extension portion
is on the housing perimeter portion.
9. The trim panel assembly of claim 3 wherein the extension portion
and the at least one of the skins are made of a first material, at
least one of the door panel and the housing panel being made of a
second material more rigid than the first material.
10. The trim panel assembly of claim 1 wherein the bumper comprises
a first portion on the door and a second portion facing the first
portion and being located on the housing.
11. The trim panel assembly of claim 9 wherein the first material
is an elastomer and the second material is rigid polymeric
material.
12. The trim panel assembly of claim 1 wherein the door is a glove
box door and the housing is a glove box compartment.
13. The trim panel of claim 1 wherein the bumper and the at least
one skin are made of the same material.
14. The method of claim 1 further comprising providing an extension
portion extending between and connecting the bumper and at least
one skin with the bumper, the at least one skin and the extension
portion being formed together within the same mold and being made
of a first material which is less rigid than the material used to
form at least one of the panels.
15. A method for making trim panel assembly comprising a housing
panel having a perimeter portion defining an opening and a housing
skin covering at least a portion of the housing panel, and a door
connectable with the housing which is moveable between a first
portion wherein the door closes the opening to a second position
wherein the door provides access to the opening, said method
comprising: injecting a first plastic material into an injection
mold to form one of the housing and the door; injecting a second,
less rigid, plastic material into the mold to form (i) one of the
housing skin and the door skin, and (ii) a bumper disposed between
the housing and the door, wherein the bumper and the one skin are
made during the same injection molding step.
16. A method for making trim panel assembly, said method
comprising: forming a housing comprising a housing panel having a
perimeter portion defining an opening; forming a housing skin
covering at least a portion of the housing panel; forming a door
panel connectable with the housing which is moveable between a
first position wherein the door closes the opening to a second
position wherein the door panel provides access to the opening;
forming a door skin covering at least a portion of the door panel;
and forming a bumper disposed between the housing and the door
panel, wherein the bumper and at least one of the skins are made
during the same injection molding step.
17. The method of claim 16, wherein the forming a housing step
comprises injecting a first plastic material into an injection
mold, the forming a housing skin step comprises injecting a second
plastic material into the injection mold; and the forming a bumper
step comprises injecting the second plastic material into the
injection mold.
18. The method of claim 16, wherein the forming a door panel step
comprises injecting a first plastic material into an injection
mold, the forming a door skin step comprises injecting a second
plastic material into the injection mold; and the forming a bumper
step comprises injecting the second plastic material into the
injection mold.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a division of U.S. application Ser. No.
10/852,276, filed May 24, 2004 and entitled "Trim Panel Assembly
Having an Integrated Door Bumper and Method of Manufacture."
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to trim panel assembly having
an integrated door bumper and a method of manufacturing the
same.
[0004] 2. Background Art
[0005] Trim panel doors have been used to close openings in
vehicles. For instance, trim panel doors have been used to close
openings in vehicle storage compartments, ash trays, and cup
holders. A quite common example of such a use is the use of a trim
panel door, such as a glove box door, to close a glove box opening.
A glove box door is typically connected with a housing having an
opening. The opening provides access to a glove box compartment.
The door when in an open position provides access to the
compartment and when closed covers the opening preventing access to
the compartment.
[0006] To prevent rattling and undesirable noises associated
therewith, elastomeric bumpers have been provided, typically placed
on the housing perimeter forming the opening. These bumpers are
typically separately manufactured and are press-fit into a small
opening in the perimeter of the housing. This press fitting
provides an extra step and an extra part during the manufacturing
process, thus increasing cost and complexity of manufacture.
[0007] It would be desirable to provide a trim panel assembly
having a door wherein the operability of a bumper is provided
without having to provide an added part, such as a press-fit
bumper.
SUMMARY OF THE INVENTION
[0008] In at least one embodiment, the present invention relates to
a method for making trim panel assembly. The method comprises
providing a housing comprising a housing panel having a perimeter
portion defining an opening and a housing skin covering at least a
portion of the housing panel. The method further comprises
providing a door connectable with the housing which is moveable
between a first position wherein the door closes the opening to a
second position wherein the door provides access to the opening.
The door comprises a door panel and a door skin covering at least a
portion of the door panel. The method further comprises providing a
bumper disposed between the housing and the door. The bumper and at
least one of the skins are made during the same injection molding
step.
[0009] In at least one embodiment, the bumper may be located on the
door.
[0010] In at least another embodiment, the bumper may be located on
the housing perimeter portion.
[0011] In at least another embodiment, an extension portion may
extend between and connect the bumper and either the door skin or
the housing skin.
[0012] In at least another embodiment, the extension portion may
extend through the door panel or the housing panel.
[0013] In at least another embodiment, the extension portion may
extend around an edge of the door panel.
[0014] In at least one embodiment, the bumper may comprise a first
portion on the door and a second portion facing the first portion
and being located on the housing.
[0015] In at least another embodiment, the door may be a glove box
door and the housing may be a glove box compartment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 illustrates a perspective view of one embodiment of
an instrument panel for a motor vehicle in accordance with the
present invention;
[0017] FIG. 2 illustrates a view along line 2-2 of FIG. 1 with the
door in a first position;
[0018] FIG. 3 is a view similar to FIG. 2 showing the door in a
second position;
[0019] FIG. 4 illustrates a front view of a portion of the
instrument panel of FIG. 1 with the door removed;
[0020] FIG. 5 is a view similar to FIG. 2 illustrating a second
embodiment of the present invention;
[0021] FIG. 6 is a view similar to FIG. 2 illustrating a third
embodiment of the present invention;
[0022] FIG. 7 is a view similar to FIG. 2 illustrating a fourth
embodiment of the present invention; and
[0023] FIG. 8 is a view similar to FIG. 2 illustrating a fifth
embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
[0024] As required, detailed embodiments of the present invention
are disclosed herein. However, it is to be understood that
disclosed embodiments are merely exemplary of the invention that
may be embodied in various alternative forms. The Figures are not
necessarily to scale, some features may be exaggerated or minimized
to show details of particular components. Therefore, specific
structural or functional details disclosed herein are not be
interpreted as limiting, but merely as a representative basis for
the claims and/or a representative basis for teaching one skilled
in the art to variously employ the present invention.
[0025] Moreover, except for otherwise expressly indicated, all
numeral quantities in this description and in the claims indicating
amounts or conditions are to be understood as modified by the work
(about) in describing the broader scope of the invention. Practice
within the numerical limits as stated is generally preferred. Also,
unless expressly stated to the contrary, percents, "parts of," and
ratio values are by weight and the description of a group or class
of materials as suitable or preferred for a given purpose in
connection with the invention implies that mixtures of any two or
more members of the group or class may be equally suitable or
preferred.
[0026] Referring to FIGS. 1 and 2, there is illustrated a motor
vehicle trim panel 10, such as an instrument panel, that is located
essentially between a windshield (not shown) and an occupant
compartment 12. While the trim panel is being illustrated as an
instrument panel 10, it should be understood that other trim
panels, such as those used to close vehicle compartments, such as
ash trays and cup holders, can enjoy the benefits of the present
invention. The panel 10 generally comprises a substrate 14 having a
first surface 15 and a second surface 17. The first surface 15 of
the substrate 14 faces the occupant compartment 12 and is covered
at least in part by a cover skin 16. The substrate 14 can be made
of any suitable material such as a relatively hard, relatively
rigid material like polypropylene, polyethylene, TPO, PC
(Polycarbonate), PC/ABS, ABS and SMA. The cover skin 16 may also be
made of any suitable relatively non-rigid relatively soft material
such as TPE, TEE, EPDM and any other suitable elastomeric
materials.
[0027] The instrument panel 10 includes a glove box, generally
indicated at 20. The glove box 20 comprises a glove box door 22
connected, preferably hingedly connected in at least one
embodiment, to a glove box compartment 24. The glove box
compartment 24 has a housing portion 23 made of the substrate
material (i.e. the housing portion 23 is part of the substrate 14).
In at least one embodiment, the housing portion 23 comprises four
side walls 23a and a back wall 23b, as best shown in FIG. 4, that
forms a storage unit 25 of the glove box compartment 24. It should
be readily understood that other suitable storage unit
configurations could be used, such as a substrate unit formed on
the door 22 that pivots open when the door is opened.
[0028] The glove box compartment 24 has a perimeter portion 32,
shown in the FIG. 4 to be a flange. The flange 32 defines an
opening 34. The glove box opening 34 provides access to the storage
unit 25 of the glove box compartment 24.
[0029] As best seen in FIG. 2, the glove box compartment 24 and the
glove box opening 34 are closeable and coverable by the glove box
door 22. When the door 22 is opened, as shown in FIG. 3, the
opening 34 and storage unit 25 are accessible by the vehicle
occupants. Referring again to FIG. 2, the glove box door 22
comprises a door panel 26 having a first surface 27 and a back
surface 29. The first surface 27 of the door panel 26 faces the
occupant compartment 12 and is covered, at least in part, by a door
skin 28. The door panel 26 also includes an upper edge surface 31
that extends between and connects the surfaces 27 and 29 of the
door panel 26. In at least one embodiment, the door panel 26 is
made of the same material as the housing portion 23, ie., the
substrate. It should be understood however that the door panel 26
and the housing portion 23 could be made of different materials.
The door skin 28, in at least one embodiment, is made of the same
material as the cover skin 16. It should be understood however that
the door skin 28 and the cover skin 16 could be made of different
materials.
[0030] The instrument panel 10 includes at least one bumper 30. The
bumper 30 provide a biasing effect between the glove box door 22
and the glove box compartment 24. The bumper 30 urges the door 22
away from the compartment 24 to prevent unwanted and unnecessary
noise and rattling during vehicle operation. While only two bumpers
30 are shown, it should be understood that more or fewer bumpers 30
could be provided, as desired. As will be described further below,
the bumpers 30 are made of the same material as either, or both, of
the cover skin 16 and/or the door skin 28. The bumpers 30 can be
made simultaneously with one of the skins 16 or 28 during a
two-shot injection molding process, as will be described further
below.
[0031] As shown in FIGS. 2-4, the bumpers 30, or bumper as the case
may be, are provided on the face of the flange 32 and face towards
the door 22. Extension portions 36 extend between and connect the
cover skin 16 and the bumpers 30. In the embodiment, the extension
portions 36 are made of the same material, and are made during the
same molding process, as the bumpers 30 and the cover skin 16. In
this embodiment, the extension portions 26 are located on the
perimeter portion, i.e., flange 32, of the glove box compartment 24
facing the occupant compartment 12.
[0032] In another embodiment, as illustrated in FIG. 5, if it
desirable to hide the extension portions 36, the extension portions
36 can extend through the flange 32 of the glove box compartment 24
at a first location and then extend along a back surface 40 of the
flange 32, facing away from the occupant compartment, and then back
through a second location of the flange 32. In this embodiment, the
second location is below the first location.
[0033] In the embodiments illustrated in FIGS. 2-5, the bumpers 30
are made of the same material as the skin 16. The bumpers 30 and
the skin 16 are made simultaneously during a two-shot injection
molding process, as will be described further below.
[0034] In another embodiment, the bumpers 30 could be placed on the
door 22 instead of on the glove box compartment 24. In one of these
embodiments, as shown in FIG. 6, the extension portion 36 extend
around the top edge 31 of the door panel 26 and down a back surface
29 of the door panel 26. In an alternative embodiment, as shown in
FIG. 7, the extension portions 36 could extend through the door
pane 26, from the front surface 27 to the back surface 29, so that
the extension portions 36 are not visible to the eye. In the
embodiments illustrated in FIGS. 6 and 7, the bumpers 30 are made
of the same material as the door skin 28. The bumpers 30 and the
door skin 28 are made simultaneously during a two-shot injection
molding process, as will be described further below.
[0035] In yet another embodiment, as illustrated in FIG. 8, the
bumpers 30 have a first portion 30a located on the door 22 and a
second portion 30b located on the housing 24. In this embodiment,
the bumpers 30a and 30b are able to be made in a smaller dimension
then the bumpers 30 in the other embodiments. For instance, the
bumpers 30 in this embodiment can have average heights of 0.1 to
1.5 mm and average widths of 0.5 to 4.0 mm, whereas the bumpers 30
in the other embodiments have average heights of 0.2 to 3.0 mm and
average widths of 0.5 to 4.0. While the extension portions 36 are
shown in FIG. 8 to be hidden from view, the extension portions 36
could extend either around the upper edge surface 37 on the door
panel 26, on the face of the flange 32, or both and not through the
door panel and/or flange 32. In this embodiment, the bumper 30a is
made of the same material as the door skin 28 and the bumper 30b is
made of the same material as skin 16. The bumper 30b and the skin
16 are made simultaneously during a two-shot injection molding
process, as will be described further below. The bumper 30a and the
door skin 26a are made simultaneously during a two-shot injection
molding process, as will be described further below.
[0036] A method of forming the bumpers 30, 30a and/or 30b using a
multi-shot or two-shot injection molding process will now be
described. Such a process is generally described in U.S. patent
application Ser. No. 10/131,015, assigned to Lear Corporation, is
incorporated by reference herein in its entirety. The process
allows the manufacture of assembly of at least one bumper to be
integrated with the manufacturer and/or assembly of a trim
component to improve quality, reduce manufacturing complexity, and
reduce costs.
[0037] In a two-shot injection molding process, a first type of
material is injected into an injection molded mold to form either
the door panel 26 or the instrument panel 10 with the glove box
compartment 24. And a second type material is injected into the
injection molding mold to form one of the cover skin 16 or door
skin 28, along with the bumpers 30, 30a and/or 30b and the
extension portions 36. The mold may include one or more cams or
slides that are actuated to create relief cavities to which the
second material flows. Alternatively, different mold cavities may
be employed for the first and second shots. For instance, a portion
of the mold having material from the first shot may be indexed to a
second position and made into another mold portion having
appropriate relief cavities before injecting the second type
material.
[0038] While embodiments of the invention have been illustrated and
described, it is not intended that these embodiments illustrate and
describe all possible forms of the invention. Rather, the words
used in the specification are words of description rather than
limitation, and it is understood that various changes may be made
without departing from the spirit and scope of the invention.
* * * * *