U.S. patent application number 11/162845 was filed with the patent office on 2007-03-29 for multi-piece vehicle interior trim panel.
This patent application is currently assigned to LEAR CORPORATION. Invention is credited to Glenn A. Cowelchuk, Randy S. Reed, Jerry G. Yatros.
Application Number | 20070067994 11/162845 |
Document ID | / |
Family ID | 37892100 |
Filed Date | 2007-03-29 |
United States Patent
Application |
20070067994 |
Kind Code |
A1 |
Cowelchuk; Glenn A. ; et
al. |
March 29, 2007 |
MULTI-PIECE VEHICLE INTERIOR TRIM PANEL
Abstract
The present invention provides a method for making a multi-piece
vehicle interior trim panel. In at least one embodiment, the method
comprises providing a major panel having a major substrate, a
sprayed urethane major skin layer disposed over at least a portion
of the major substrate, and a foam layer between the major
substrate and the major skin layer. The method further includes
forming a minor panel by spraying polyurethane material proximate a
relatively small mold surface to form a sprayed urethane minor skin
layer, spraying expandable polyurethane material onto the minor
skin layer to form a first resilient layer, placing a mounting
substrate onto the first resilient layer, and spraying expandable
polyurethane material onto the first resilient layer and the
mounting substrate to form a second resilient layer. The method
further comprises removing the minor panel from the mold and
securing the minor panel to the major panel portion.
Inventors: |
Cowelchuk; Glenn A.;
(Chesterfield Township, MI) ; Reed; Randy S.;
(Fair Haven, MI) ; Yatros; Jerry G.; (St Clair
Shores, 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: |
37892100 |
Appl. No.: |
11/162845 |
Filed: |
September 26, 2005 |
Current U.S.
Class: |
29/897.2 |
Current CPC
Class: |
B60R 11/0264 20130101;
B60R 2011/0288 20130101; B60R 11/0241 20130101; B60R 11/02
20130101; Y10T 29/49622 20150115 |
Class at
Publication: |
029/897.2 |
International
Class: |
B21D 53/88 20060101
B21D053/88 |
Claims
1. A method for making a multi-piece vehicle interior trim panel,
said method comprising: providing a major panel having a major
substrate, a sprayed urethane major skin layer disposed over at
least a portion of the major substrate, and a layer of foam between
the major substrate and the major skin layer, the major panel
having a mounting portion having at least one mounting opening;
forming a minor panel, said minor panel being formed by: providing
a spray mold having a mold surface smaller than the outer surface
of the major skin layer; spraying polyurethane material proximate
the mold surface to form a sprayed urethane minor skin layer having
a height (H), an exterior surface, and an interior surface;
spraying a first portion of expandable polyurethane material onto
the minor skin layer to form a first resilient layer; placing a
mounting substrate onto the first resilient layer; and spraying a
second portion of expandable polyurethane material onto the first
resilient layer and the mounting substrate to form a second
resilient layer; removing the minor panel from the mold; and
securing the minor panel to the mounting portion of the major
panel, wherein a package space (X) is disposed between the interior
surface of the minor skin layer and the mounting portion of the
major substrate, with at least one of (i) the height (H) of the
minor skin being less than 12 mm and (ii) the package space (X)
being less than 5 mm.
2. The method of claim 1 wherein the mounting substrate is placed
onto the first resilient layer before the first resilient layer has
substantially cured.
3. The method of claim 1 wherein the mounting substrate has at
least one projection and wherein securing the minor panel to the
major panel comprises inserting the projection through the mounting
opening of the major panel and securing the projection to the major
panel.
4. The method of claim 3 wherein the mounting substrate comprises a
plate, the projection extending from the plate, the plate having at
least one plate opening therein.
5. The method of claim 4 wherein spraying a second portion of
expandable polyurethane material onto the first resilient layer and
the mounting substrate comprises spraying the second portion onto
the plate and through the plate opening.
6. The method of the claim 3 wherein the projection is heat-staked
to the major panel portion.
7. The method of claim 4 wherein the resilient layers each have a
density of 0.1 to 0.75 g/cm.sup.3.
8. The method of claim 7 wherein the skin layer each have a density
of 0.85 to 1.2 g/cm.sup.3.
9. The method of claim 7 wherein the first resilient layer has an
average thickness of 0.3-4.5 mm.
10. The method of claim 9 wherein the second resilient layer has an
average thickness of 0.3 to 3 mm.
11. The method of claim 10 wherein the minor skin layer has a n
average thickness of 0.3 to 8 mm.
12. The method of claim 11 wherein the plate has a thickness of 0.2
to 3 mm.
13. An automobile interior panel made by the method of claim 1.
14. An automobile instrument panel made by the method of claim
1.
15. A method for making a multi-piece vehicle interior trim panel,
said method comprising: providing a major panel having a major
substrate and major skin layer disposed over at least a portion of
the major substrate, the major substrate having a mounting portion;
forming a minor panel, said minor panel being formed by: spraying
polyurethane material proximate a mold surface to form a sprayed
urethane minor skin layer having a height (H); placing a mounting
substrate proximate the minor skin layer; and spraying expandable
polyurethane material over the mounting substrate to form a
resilient layer to secure the mounting substrate to the minor skin
layer; and securing the minor panel to the mounting portion of the
major panel, wherein a package space (X) is present between the
minor skin layer and the mounting portion, with at least one of the
height (H) being less than 12 mm or the package space (X) being
less than 5 mm.
16. The method of claim 15 wherein the mounting substrate has at
least one projection and wherein securing the minor panel to the
major panel comprises securing the projection to mounting portion
of the major panel.
17. The method of claim 15 wherein the minor skin layer has an
average thickness of 0.3 to 8 mm.
18. The method of claim 15 wherein the resilient layers each have a
density of 0.1 to 0.75 g/cm.sup.3.
19. The method of claim 18 wherein the skin layer each have a
density of 0.85 to 1.2 g/cm.sup.3.
20. A method for making a multi-piece vehicle interior trim panel,
said method comprising: providing a major panel having a major
substrate and sprayed urethane major skin layer disposed over at
least a portion of the major substrate, the major panel having at
least one mounting opening; forming a minor panel, said minor panel
being formed by: providing a spray mold having a mold surface
smaller than the outer surface of the major skin layer; spraying
polyurethane material proximate the mold surface to form a
polyurethane skin layer; spraying a first portion of expandable
polyurethane material onto the skin layer to form a first resilient
layer; placing a mounting substrate proximate the first resilient
layer; and spraying a second portion of expandable polyurethane
material onto the first resilient layer and the mounting substrate
to form a second resilient layer; and securing the minor panel to
the major panel.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to multi-piece vehicle interior trim
panels.
[0003] 2. Background Art
[0004] The use of interior trim panels in automotive applications
is relatively well known. One relatively typical vehicle interior
trim panel comprises a relatively rigid substrate having a flexible
thin plastic skin disposed over at least an interior facing portion
of a surface of the substrate. Spraying material, such as a
polyurethane composition, onto a mold provides a skin having
several advantages. When a softer touch for the panel is desired,
foam has been provided between the substrate and the skin. The
distance, or space, between the skin and the substrate is known as
the package space (X).
[0005] A common method of providing the foam is to employ the use
of a foam in place process. Various areas of a trim panel of a
vehicle, such as the border area below and/or around the center
stack of an instrument panel, may have a relatively short height
(H) and/or a relative small package space (X). For portions of trim
panels having a height (H) of less than 12 mm and/or a package
space (X) of less than 5 mm, the typical foam in place process may
have difficulty being employed. This is because foam flow through
these areas having a relatively small height (H) and/or package
space (X) can be hindered and unreliable.
[0006] As such, it can be difficult to provide a soft touch sprayed
skin panel due to the unreliability and difficulties with the foam
in place process for panels having portions with a relatively small
height (H) and/or a package space (X). A relatively common result
is that, due to the poor foam coverage in these areas, the panel
can have uneven softness zones. As part of overall craftsmanship,
it is desirable to provide a soft touch sprayed skin panel having
relatively even softness zones with consistent skin material to
ensure consistent color, gloss and grain match.
SUMMARY OF THE INVENTION
[0007] The present invention provides a method for making a
multi-piece vehicle interior trim panel.
[0008] In at least one embodiment, the method comprises providing a
major panel having a major substrate, a sprayed urethane major skin
layer disposed over at least a portion of the major substrate, and
a layer of foam between the major substrate and the major skin
layer. The major panel portion may have at least one mounting
opening. In this embodiment, the method further includes providing
a spray mold having a mold surface smaller than the outer surface
of the major skin layer and spraying polyurethane material
proximate the mold surface to form a sprayed urethane minor skin
layer. In this embodiment, the method further includes spraying a
first portion of expandable polyurethane material onto the minor
skin layer to form a first resilient layer, placing a mounting
substrate onto the first resilient layer, and spraying a second
portion of expandable polyurethane material onto the first
resilient layer and the mounting substrate to form a second
resilient layer. In this embodiment, the method further comprises
removing the minor panel portion from the mold and securing the
minor panel portion to the major panel portion.
[0009] In at least another embodiment, the method comprises
providing a major panel having a major substrate, a sprayed
urethane major skin layer disposed over at least a portion of the
major substrate, and a layer of foam between the major substrate
and the major skin layer. In this embodiment, the major panel has a
mounting portion having at least one mounting opening. In this
embodiment, the method further includes forming a minor panel by
providing a spray mold having a mold surface smaller than the outer
surface of the major skin layer and spraying polyurethane material
proximate the mold surface to form a sprayed urethane minor skin
layer having a height (H), an exterior surface. In this embodiment,
the method further comprises and an interior surface, spraying a
first portion of expandable polyurethane material onto the minor
skin layer to form a first resilient layer, and spraying a second
portion of expandable polyurethane material onto the first
resilient layer and the mounting substrate to form a second
resilient layer. In this embodiment, the method further comprises
removing the minor panel from the mold and securing the minor panel
to the mounting portion of the major panel. In this embodiment, the
minor panel has a package space (X) disposed between the interior
surface of the minor skin layer and the mounting portion of the
major substrate, with at least one of (i) the height (H) of the
minor skin being less than 12 mm and (ii) the package space (X)
being less than 5 mm.
[0010] In at least yet another embodiment, the method comprises
providing a major panel having a major substrate and major skin
layer disposed over at least a portion of the major substrate, with
the major substrate having a mounting portion. In this embodiment,
the method further comprises forming a minor panel by spraying
polyurethane material proximate a mold surface to form a sprayed
urethane minor skin layer having a height (H), placing a mounting
substrate proximate the minor skin layer, and spraying expandable
polyurethane material over the mounting substrate to form a
resilient layer to secure the mounting substrate to the minor skin
layer. In this embodiment, the method further comprises securing
the minor panel to the mounting portion of the major panel, wherein
a package space (X) is present between the minor skin layer and the
mounting portion. In this embodiment, at least one of (i) the
height (H) is less than 12 mm or (ii) the package space (X) is less
than 5 mm.
[0011] While exemplary embodiments in accordance with the invention
are illustrated and disclosed, such disclosure should not be
construed to limit the claims. It is anticipated that various
modifications and alternative designs may be made without departing
from the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is perspective view of an instrument panel according
to an embodiment of the invention for use in motor vehicle;
[0013] FIG. 2 is a cross sectional view of the panel taken along
the line 2-2 of FIG.
[0014] FIG. 3 is a view similar to FIG. 2 showing components of the
panel is an unassembled state;
[0015] FIG. 4 is a schematic view of a spray mold and a spray
assembly for use in forming a panel component of the panel of FIG.
1, wherein the spray assembly is shown applying material on the
tool to form a skin layer;
[0016] FIG. 5 is a schematic view of the tool showing application
of expandable material onto the skin layer to form a portion of a
resilient layer;
[0017] FIG. 6 is a schematic view of the tool showing application
of a mounting substrate onto the portion of resilient layer shown
in FIG. 5;
[0018] FIG. 7 is a schematic view of the tool showing application
of expandable material onto the first resilient layer to form
another portion of the resilient layer; and
[0019] FIG. 8 is a perspective view of a component illustrated in
FIG. 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
[0020] As required, detailed embodiments of the present invention
are disclosed herein. However, it is to be understood that the
disclosed embodiments are merely exemplary of the invention that
may be embodied in various alternative forms. The figures are not
necessarily of scale, some features may be exaggerated or minimized
to show details of particular components. Therefore specific
structural and functional details disclosed herein are not to 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. Moreover,
except where otherwise expressly indicated, all numerical
quantities in this description and in the claims indicating amounts
of materials or conditions of reactions and/or use are to be
understood as modified by the word "about" in describing the
broader scope of this invention. Practice within the numerical
limits stated is generally preferred. Also, unless expressly stated
to the contrary, percent "parts of," and ratio values are by weight
and the description of a group or class of materials as suitable
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.
[0021] FIGS. 1 and 2 show a multi-piece interior vehicle trim
component, such as an instrument panel 10, according to the
invention for use with a motor vehicle 12. In at least one
embodiment, the instrument panel 10 has a major panel 14 and a
minor panel 16 connected to the major panel.
[0022] In at least one embodiment, the minor panel 16 has a size
constraint that makes employing a foam in place process to form a
foam layer in the minor panel unreliable. Examples of such a
constraint can be the minor panel 16 having at least one of a
height (H) of less than 12 mm or a package space (X) having at
least a portion of less than 5 mm. In at least one embodiment, the
minor panel 16 has a height (H) of 1-10 mm, and in yet another
embodiment of 5-7 mm. In at least one embodiment, the minor panel
16 has at least a portion having a package space (X) of 0.5-4 mm,
and in yet other embodiments of 1-3 mm.
[0023] The minor panel 16 is shown in the Figures to have a
rectangular shape. However, it should be understood that the minor
panel 16 can have any suitable shape, such as a U-shape, a thin
walled block-shape, an S-shape, a V-shape, etc. Furthermore, while
the vehicle trim component is being illustrated as an instrument
panel 10, it should be understood that the vehicle trim component
could be other types of panels, such as doors, consoles and other
vehicle interior trim panels.
[0024] Referring to FIG. 2, in at least one embodiment, the major
panel 14 includes a rigid major substrate 20 having a first portion
22 and at least one connector portion 24 extending from the first
portion. The connector portion 24 includes a mounting opening
26.
[0025] As best shown in the embodiment illustrated in FIG. 3, the
major panel 24 has two connector or mounting portions, illustrated
as tabs, extending from the rigid substrate 20. It should be
understood that any number of connector portions 24 could be
employed and that the connector portions can take any suitable
shape, such as a rectangular plate having one or more mounting
holes therein. Furthermore, the connector tabs 24, (i.e., connector
portion) could extend elsewhere than from the major substrate, so
long as the connector portion can secure the minor panel 16
relative to the major panel 14.
[0026] Referring again to FIG. 2, the major panel 14 further
includes, in at least one embodiment, a foam layer 28 secured to
the major substrate 20 and a major skin layer 32 secured to the
foam layer 28 to cover the foam layer 28 and provides an exterior
apparent surface. As can be seen in FIG. 2, the major skin layer 32
can be provided with an end portion that contacts the first portion
22 of the major substrate 20 to act as a "foam shut-off."
[0027] The major substrate 20 is a structural member that provides
support for the remainder of the major panel 14, and may comprise
any suitable material. For example, the major substrate 20 may be
made of plastic or reinforced plastic such as fiberglass reinforced
polyurethane. Additional examples of suitable plastics, besides
polyurethane, include polypropylene, polyethylene, acrylonitrile
butadiene styrene (ABS), polycarbonate (PC), and ABS/PC blends. In
at least one embodiment, the major substrate 14 may have a general
thickness of between 0.5 to 5 mm, in another embodiment 1.0 to 3.5
mm, and in yet another embodiment 2.0 to 3.0 mm.
[0028] In the illustrated embodiment, the foam layer 28 is adhered
between the major substrate 20 and the major skin layer 32. The
foam layer 28 generally contours to the major substrate 20. The
foam layer 28 helps to provide a soft feel to the major panel 14 of
the instrument panel 10. The foam layer 28 may comprise any
suitable foam material. For example, the foam layer 28 may comprise
a foam in place polyurethane foam. In at least one embodiment, the
density of the foam layer 28 is in the range of 0.05 to 0.20 grams
per cubic centimeter (g/cm.sup.3). In at least one embodiment the
foam layer 28 has a thickness of 3.0 to 25 mm, and in at least
another embodiment 5 to 15 mm, and in yet another embodiment 6 to
10 mm. The foam layer 28 may have varying thicknesses.
[0029] The major skin layer 32 is adhered to the foam layer 28.
Moreover, the major skin layer 32 is configured to provide a
covering over, and is generally contoured to, the foam layer 28 and
may comprise any sufficiently dense material. For example, the
major skin layer 32 may be a solid layer that comprises an aromatic
or aliphatic compound. As a more specific example, the major skin
layer 32 may be made of an elastomer such as polyurethane. As an
even more specific example, the major skin layer 32 may be sprayed
urethane. Furthermore, the major skin layer 32 may have any
suitable thickness and density. For example, the major skin layer
32 may have a general thickness in the range of 0.4 to 3 mm and a
density in the range of 0.85 to 1.2 g/cm.sup.3. In at least one
embodiment, the major skin layer 32 may have a shore A hardness of
50 to 80. In at least one embodiment, the major skin layer 32 has a
general thickness in the range of 0.5 to 1.2 mm, and a density in
the range of 0.95 to 1.1 g/cm.sup.3.
[0030] An optional coating (not shown) may be disposed over the
major skin layer to protect the major skin layer 32 and/or to
provide a decorative surface for the instrument panel 10. For
example, the optional coating (not shown) may be used to inhibit
sunlight and/or other ultraviolet light from reaching the major
skin layer 32. As another example, the optional coating may be used
as a paint to provide a desired color and/or texture to the major
panel 14. While the optional coating may comprise any suitable
material, in at least one embodiment of the invention, the optional
coating is made of an aliphatic polyurethane composition.
Furthermore, the optional coating may have any suitable thickness,
such as a thickness of approximately 0.5 to 1.5 mil.
[0031] The major panel 14 may be made in any suitable manner. In at
least one suitable manner, the major skin layer 32 is formed by
spraying suitable material onto a spray mold. The major skin layer
32 is then secured to the major substrate 20 via the foam layer 28.
In at least one embodiment, the foam layer 28 is disposed between
the major skin layer 32 and the major substrate 20 via a foam in
place process.
[0032] Referring to FIG. 2, in at least one embodiment, the minor
panel 16 includes a minor skin layer 42, a resilient layer 44
disposed between the minor skin layer 42 and the connector portion
24 of the major substrate 20, and a mounting plate 46 adhered to
the resilient layer 44 and connected to the connector portion 24.
As is shown in FIG. 2, space may be present, at least in certain
locations, between the resilient layer 44 and the connector portion
24.
[0033] The minor skin layer 42 is configured to provide a coating
over, and is generally contoured to, the resilient layer 44. The
minor skin layer 42 can be made of the same or similar material as
the major skin layer 32 and may comprise any sufficiently dense
sprayed urethane material. For example, the minor skin layer 42 may
be a solid layer that comprises an aromatic or aliphatic compound.
As a more specific example, the minor skin layer 42 may be made of
an elastomer such as polyurethane. As an even more specific
example, the minor skin layer 42 may be sprayed urethane.
Furthermore, the minor skin layer 42 may have any suitable density.
For example, the minor skin layer 42 may have a density in the
range of 0.85 to 1.2 g/cm.sup.3. In at least one embodiment, the
minor skin layer 42 has a density in the range of 0.95 to 1.1
g/cm.sup.3. In at least one embodiment, the minor skin layer has a
shore A hardness of 50 to 80. An optional coating (not shown)
similarly with the major skin layer 32, could be applied over the
minor skin layer 42.
[0034] In at least the illustrated embodiment, the minor skin layer
42 is thicker than the major skin layer 32. This may help to
provide a more rigid part for dimensional stability. While the
minor skin layer 42 may have any suitable thickness, in at least
one embodiment, the minor skin layer has an average thickness in
the range of 0.3 to 8 mm, and in another embodiment 0.4 to 3 mm,
and in yet another embodiment of 0.5 to 1.25 mm.
[0035] The mounting plate 46, in at least the illustrated
embodiment as shown in FIG. 2, includes a plate portion 60 and at
least one mounting projection 62 depending from the plate 60. While
two mounting projections 62 are shown in FIGS. 3 and 8, it should
be understood that more or less projections could be used, as
desired. The mounting projection 62 can be secured to the connector
portion 24 via any suitable connection means, such as by heat
staking, as is shown in FIG. 2.
[0036] In at least one embodiment, the mounting plate 46 includes a
plurality of, such as four, equidistant ribs 66 depending from
plate portion 60 and disposed about the projection to help
securably mount and locate the projection to the opening 26 and the
connector portion 24. It should be understood that ribs 66 could be
located on the connector portion 24 either in addition to, or
instead of, the ribs 66 on the plate portion 60.
[0037] As best shown in FIG. 2, the plate portion 60 has a
plurality of openings 68 therein. As will be explained further
below, the openings 68 can assist in securing the plate 60 to the
resilient layer 44. The mounting plate 46 may be made of any
suitable material such as plastic or metal. In at least one
embodiment, the plate portion 60 has a thickness of 0.2-3 mm, and
in another embodiment 0.75-1.25 mm. In at least one embodiment, the
mounting plate 46 is made of the same or a similar material as that
of the major substrate 22.
[0038] The projections 62 on the mounting plate 46 can be secured
to the connector portion 24 of the substrate 20 via any suitable
means, such as heat staking as is shown in FIG. 2. The distance
between the mounting portion 24 and the minor skin layer 42 is
known as the package space (X). As can be understood, a substantial
portion or even all of the package space (X) could be less than 5
mm, and in at least another embodiment between 0.5 and 4 mm, and in
yet at least another embodiment between 1 to 3 mm.
[0039] In the illustrated embodiment, the resilient layer 44 is
adhered to the mounting substrate 46 and the minor skin layer 42.
The resilient layer 44 may help to provide a soft feel to the minor
panel 16. The resilient layer 44 may comprise any suitable sprayed
expanded polyurethane material. For example, the resilient layer 44
may comprise an expanded aromatic polyurethane elastomer. In at
least one embodiment, the density of the resilient layer 44 can be
in the range of 0.1 to 0.75 g/cm.sup.3, in another embodiment
between 0.15 to 0.5 g/cm.sup.3, and in yet another embodiment 0.2
to 0.3 g/cm.sup.3.
[0040] In at least one embodiment, the resilient layer 44 primarily
may comprise a low permeable, relatively closed cell material. In
at least one embodiment, the resilient layer 44 may comprise 35 to
75 percent closed cell structures, in at least another embodiment
40 to 65 percent closed cell structures, and in yet at least
another embodiment 45 to 55 percent closed cell structures, based
upon the entire resilient layer 44. In at least one embodiment, the
average cell structure size can vary between 0.05 mm to 3.0 mm, and
in yet other embodiments between 0.5 mm to 1.0 mm.
[0041] In at least the illustrated embodiment, the resilient layer
44 generally comprises a first portion 52 adjacent the major skin
layer 42 and a second portion 54 generally behind the first portion
42 and adjacent the connector portion 24. In at least one
embodiment, the first portion 52 of the resilient layer 44 may have
an average thickness generally between 0.3 to 4.5 mm, in other
embodiments between 1 to 4 mm and in yet other embodiments 2 to 3
mm. In at least one embodiment, the second portion 54 of the
resilient layer 44 may have an average thickness generally between
0.3 to 3 mm, in other embodiments between 0.5 to 2 mm and in yet
other embodiments 0.75 to 1.25 mm. It should be understood that the
thicknesses of the portions 52 and 54 can vary from each other, as
desired. Furthermore it should be understood that the thickness of
each portion 52 and 54, and especially for 54, can vary throughout
their portion as desired, such as is dictated by part
configuration.
[0042] Referring to FIGS. 4-6, a method of manufacturing the
instrument panel 10 will now be described. As set forth above, the
major panel 14 is made via any suitable process. The major panel 14
is made separately from the minor panel 16.
[0043] The minor panel 16 may be made by the following method. The
method of making the minor panel 16 may begin by spraying an
optional mold release agent and then an optional coating (not
shown) on a spraying mold tool 70 using any suitable device, such
as robotic low pressure (such as 10 to 40 psi) spray assembly 72
having one or more moveable spray nozzles.
[0044] The tool 70 has a spray receiving surface 76 generally
corresponding to the exterior surface of the minor panel 14. The
spray surface 76 has, in at least one embodiment, a height (H) of
less than 12 mm, and in at least another embodiment between 1 and
10 mm, and in yet at least another embodiment between 4 to 8 mm.
The tool 70 may be heated to any suitable temperature if
desired.
[0045] Next, the method involves spraying skin layer forming
material onto the spray receiving surface 76 (or the optional
coating or the optional mold release agent) to form minor skin
layer 42. A source of skin layer forming material (not shown) is in
fluid communication with the spray assembly 72. The skin layer
forming material may be any suitable sprayable substance and may be
applied using any suitable device. For example, the material may
include polyol and isocyanate, and the material may be sprayed with
a robotic high pressure (such as 400 to 2,000 psi) spray assembly
72 having one or more moveable spray nozzles. As a result, the skin
layer 42 may be formed of polyurethane. When the optional coating
(not shown) is omitted from the minor panel 14, the minor skin
layer 44 is preferably a colored aliphatic polyurethane.
[0046] Referring to FIG. 5, in at least one embodiment the method
then involves introducing expandable material onto the minor skin
layer 42 to form resilient layer 44, which bonds to the minor skin
layer 42. The expandable material may comprise any suitable
expandable material. In at least one embodiment, the expandable
material comprises any suitable expandable polyurethane material
and may be applied in any suitable manner. For example, the
expandable polyurethane material may comprise polyol, isocyanate
and a blowing agent such as water and/or a readily volatile organic
substance, such as a delayed-action amine catalyst.
[0047] Furthermore, the expandable material may be sprayed with a
robotic spray assembly 82 which receive the expandable material
from a source of expandable material (not shown) in fluid
communication with the spray assembly 82. The robotic spray
assembly 82 may include one or more spray nozzles and the material
may be allowed to free rise to achieve a desired density. The
robotic spray assembly 82 may be the same type of spray assembly 72
as is used in FIG. 4. Alternatively, the same spray assembly 72 as
used in FIG. 4 could be used to spray the expandable material.
[0048] The resilient layer 44 adheres the mounting substrate 46 to
the minor skin layer 42. In at least one embodiment, the expandable
material is sprayed in two steps to form the first portion 52 of
the resilient layer 44 and the second portion 54 of the resilient
layers. In this embodiment, a first portion of expandable material
is sprayed onto the minor skin layer 42 to form a first portion 52
(FIG. 5) of the resilient layer 44. Before the first portion of
expandable material fully cures, the mounting plate 46 is placed on
the first portion 52 of sprayed expandable material. Next, a second
portion of sprayed expandable material is sprayed over the mounting
plate 60 of the mounting bracket 46 and the first layer of sprayed
expandable material. At this point, the first layer of sprayed
expandable material may have already cured or at least partially
cured into the first portion 52 of the resilient layer 44. The
second portion of the expandable material is sprayed to a
sufficient thickness to form a second portion 54 of resilient layer
44. The spraying of the second portion of the resilient layer is
illustrated in FIG. 6. After the second portion of resilient layer
44 has cured, the minor panel 16 is formed as illustrated in FIG.
7. As can be seen in the Figures, the second portion 54 of
resilient layer 44 may also fill the openings 68 in the plate
60.
[0049] In at least one embodiment, the first portion 52 of the
resilient layer 44 may have an average thickness generally between
0.3 to 4.5 mm, in other embodiments between 1 to 4 mm and in yet
other embodiments 2 to 3 mm. In at least one embodiment, the second
portion 54 of the resilient layer 44 may have an average thickness
generally between 0.3 to 3 mm, in other embodiments between 0.5 to
2 mm and in yet other embodiments 0.75 to 1.25 mm. The minor panel
16 is then secured to the connector portion 24 of the major
substrate 22 in any suitable manner, such as by heat staking the
projection(s) 62 through the mounting opening(s) 26.
[0050] Referring to FIG. 8, a perspective view of one embodiment of
mounting plate 46 is shown. Referring to FIG. 8, the mounting plate
46 includes openings 68 in the plate 60 to allow expandable
material to be sprayed therethrough to help secure the mounting
plate 46 and the second portion 54 of resilient layer 44 to the
first portion 52 of the resilient layer 44.
[0051] In at least one embodiment, the present invention provides a
soft touch sprayed skin panel having relatively even softness zones
with consistent skin material to ensure consistent color, gloss and
grain match.
[0052] Examples of other vehicle parts that may be manufactured by
the above method includes door panels, package shelves, pillar trim
panels, trim products, door covers, console covers, shelves, and
trim covers, among others.
[0053] Although separate spray assemblies 72 and 82 are shown in
the figures, the spray assemblies may be provided as a single spray
assembly. Furthermore if the material to be sprayed includes
multiple substances, the substance may be mixed at a suitable time.
For example, the substances may be mixed up stream of, within, or
down stream of the associated spray nozzles.
[0054] 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.
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