U.S. patent application number 11/538650 was filed with the patent office on 2007-04-12 for method of making an automotive trim part with applique.
This patent application is currently assigned to LEAR CORPORATION. Invention is credited to Glenn A. Cowelchuk, Todd L. DePue, David Dooley, Michael J. Hier, Randy S. Reed.
Application Number | 20070080474 11/538650 |
Document ID | / |
Family ID | 35451815 |
Filed Date | 2007-04-12 |
United States Patent
Application |
20070080474 |
Kind Code |
A1 |
Cowelchuk; Glenn A. ; et
al. |
April 12, 2007 |
Method of Making An Automotive Trim Part With Applique
Abstract
The present invention provides for an improved trim part, e.g. a
bolster or trim plate, with integrated applique for use in a trim
assembly, and to a continuous two-shot molding operation that may
be performed utilizing a single mold assembly. In an exemplary
embodiment, the trim part, i.e. a bolster, includes a substrate
formed by injecting a first material into a first shot mold cavity
in a first shot of a molding operation. An applique is provided in
a second shot mold cavity then a cover is formed between the
substrate and applique by injecting into a mold chamber a second
foamed material in a second shot of the molding operation. The
formed cover is integrally molded to at least a portion of the
substrate and the applique to form a trim part with integrated
applique.
Inventors: |
Cowelchuk; Glenn A.;
(Chesterfield Township, MI) ; DePue; Todd L.;
(Brighton, MI) ; Dooley; David; (Troy, MI)
; Hier; Michael J.; (Milford, MI) ; Reed; Randy
S.; (Fair Haven, MI) |
Correspondence
Address: |
WOOD, HERRON & EVANS, LLP (LEAR)
2700 CAREW TOWER
441 VINE STREET
CINCINNATI
OH
45202
US
|
Assignee: |
LEAR CORPORATION
Southfield
MI
48034
|
Family ID: |
35451815 |
Appl. No.: |
11/538650 |
Filed: |
October 4, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10904007 |
Oct 19, 2004 |
7156437 |
|
|
11538650 |
Oct 4, 2006 |
|
|
|
Current U.S.
Class: |
264/46.4 ;
264/250; 264/255; 264/279 |
Current CPC
Class: |
B60R 2013/0281 20130101;
B60R 13/02 20130101; B60R 13/0243 20130101 |
Class at
Publication: |
264/046.4 ;
264/255; 264/250; 264/279 |
International
Class: |
B29C 44/06 20060101
B29C044/06; B29C 44/12 20060101 B29C044/12; B29C 45/14 20060101
B29C045/14 |
Claims
1. A method of forming an automotive trim part with an integrated
applique in a two-shot molding operation, comprising: molding a
substrate by injecting a first material in a first shot of the
molding operation; providing an applique; forming a mold chamber
about at least a portion of the substrate and the applique; and
molding a cover intermediate the portion of the substrate and the
applique by injecting into the mold chamber a second foamed
material in a second shot of the molding operation, the cover being
molded to at least the portion of the substrate and the applique to
form the trim part with an integrated applique.
2. The method of claim 1, wherein the step of molding a substrate
by injecting a first material includes molding the substrate by
injecting a thermoplastic polymer; and wherein the step of molding
a cover by injecting a second foamed material includes molding the
cover by injecting a foamed thermoplastic polymer.
3. The method of claim 1, wherein the step of molding a substrate
by injecting a first material includes molding the substrate by
injecting a thermoplastic polymer; and wherein the step of molding
a cover by injecting a second foamed material includes molding the
cover by injecting one of a foamed thermoplastic elastomer and
foamed polypropylene.
4. The method of claim 1, wherein the step of providing an applique
comprises providing the applique including a decorative
material.
5. The method of claim 1, wherein the step of providing an applique
comprises providing the applique having a symbol thereon.
6. The method of claim 1, wherein the formed trim part with an
integrated applique is one of a trim plate and a bolster with an
integrated applique.
7. A method of forming an automotive trim part with an integrated
applique in a continuous two-shot molding operation, comprising:
providing a mold assembly having first and second shot mold
cavities; molding a substrate by injecting a first material into
the first shot mold cavity of the mold assembly in a first shot of
the molding operation; providing the second shot mold cavity with
an applique; moving the substrate from the first shot mold cavity
to the second shot mold cavity by using at least a portion of the
mold assembly; forming a mold chamber about at least a portion of
the substrate and the applique within the second shot mold cavity
of the mold assembly; and molding a cover intermediate the portion
of the substrate and the applique by injecting into the mold
chamber a second foamed material in a second shot of the molding
operation, the cover being molded to at least the portion of the
substrate and the applique to form the trim part with an integrated
applique.
8. The method of claim 7, wherein the step of molding a substrate
by injecting a first material includes molding the substrate by
injecting a thermoplastic polymer; and wherein the step of molding
a cover by injecting a second foamed material includes molding the
cover by injecting a foamed thermoplastic polymer.
9. The method of claim 7, wherein the step of molding a substrate
by injecting a first material includes molding the substrate by
injecting a thermoplastic polymer; and wherein the step of molding
a cover by injecting a second foamed material includes molding the
cover by injecting a foamed thermoplastic elastomer or foamed
polypropylene.
10. The method of claim 7, wherein the step of providing an
applique comprises providing the applique including a decorative
material.
11. The method of claim 7, wherein the step of providing an
applique comprises providing the applique having a symbol
thereon.
12. The method of claim 7, wherein the formed trim part with an
integrated applique is one of a trim plate and a bolster with an
integrated applique.
13. The method of claim 7, wherein the step of providing a mold
assembly having first and second shot mold cavities comprises
providing a mold assembly having first and second shot mold
cavities and a core having at least one male portion adapted to
mate with each cavity, the core further being adapted to rotate;
wherein the step of molding a substrate comprises molding the
substrate by mating the at least one male portion with the first
shot mold cavity and injecting the first material into the first
shot mold cavity in the first shot of the molding operation;
wherein the step of moving the substrate comprises rotating the
substrate on the at least one male portion of the core from the
first mold cavity to the second mold cavity; and wherein the step
of forming a mold chamber comprises forming the mold chamber about
at least a portion of the substrate and the applique within the
second shot mold cavity of the mold assembly by mating the at least
one male portion with the second shot mold cavity to mold the cover
therebetween in the second shot of the molding operation.
14. The method of claim 13, wherein the step of rotating the
substrate comprises rotating the substrate about a horizontal axis
to move the substrate from the first shot mold cavity to the second
shot mold cavity.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of pending U.S. patent
application Ser. No. 10/904,007 (pending), filed Oct. 19, 2004, the
disclosure of which is hereby incorporated by reference herein.
This application is also related to U.S. Ser. No. 10/708,312, filed
Feb. 24, 2004, U.S. Ser. No. 10/904,008, filed Oct. 19, 2004, U.S.
Ser. No. 10/904,010, filed Oct. 19, 2004, U.S. Ser. No. 10/904,011,
filed Oct. 19, 2004, U.S. Ser. No. 10/904,032, filed Oct. 20, 2004,
U.S. Ser. No. 10/711,692, filed Sep. 30, 2004, U.S. Ser. No.
10/904,033, filed Oct. 20, 2004, U.S. Ser. No. 10/904,433, filed
Nov. 10, 2004, U.S. Ser. No. 10/904,409, filed Nov. 9, 2004, U.S.
Ser. No. 10/904,408, filed Nov. 9, 2004 and U.S. Ser. No.
10/904,407, filed Nov. 9, 2004.
FIELD OF THE INVENTION
[0002] The present invention pertains to a method of making trim
assemblies for automotive interiors and, more particularly, to an
automotive trim part having an integrated applique such as for use
in a trim assembly.
BACKGROUND OF THE INVENTION
[0003] It is known to provide automotive interiors with various
trim parts to enhance the aesthetic appearance of the automotive
interior, and to provide comfort to vehicle occupants. Examples of
some of these interior trim parts include instrument trim panels,
door trim panels, console panels, armrests, bolsters, handles, trim
plates, and airbag covers. To increase the aesthetic appearance of
these trim parts and to improve the comfort to vehicle occupants,
it is desired to provide at least portions of the trim parts, such
as bolsters, with appliques or decorative areas.
[0004] One primary drawback with current trim parts having
decorative areas is in the manufacturing and assembly thereof.
These trim parts, such as bolsters, typically, have been formed by
insertion of a resilient padding material beneath a pliable surface
or skin layer of decorative trim material, such as a textile or
fabric like woven cloth, vinyl, and/or leather. The preformed
resilient pad also may be secured to a rigid plastic shell and a
pliable skin layer stretched over the pad and secured to the shell
to form the decorative trim part. In other cases, padding is
omitted to provide a rigid base and a decorative trim material that
is adhesively bonded thereto. In another conventional method of
forming trim parts with decorative areas for use in trim
assemblies, a foam material may be injected between a rigid
substrate and a decorative skin layer, already joined to the
substrate. Consequently, the above noted methods are generally
costly due to the multiple components and manufacturing steps
required to make these decorative trim parts.
[0005] There is thus a need for an improved trim part with
integrated applique for use in a trim assembly, and a method for
making the same, that reduces the number of parts and the labor
required for assembly thereof thereby reducing overall
manufacturing costs.
SUMMARY OF THE INVENTION
[0006] The present invention provides for an improved trim part,
such as a bolster, with an integrated applique for use in a trim
assembly, e.g. a door trim panel assembly. It should be understood
that the trim part may include any desired automotive trim part
such as an instrument trim panel, door trim panel, console panel,
armrest, handle, trim plate, airbag cover, etc, for use in any
desired trim panel assembly, such as a door trim panel assembly,
instrument panel assembly, console assembly, etc.
[0007] To this end, the trim part is an integrated, unitary
structure that includes a substrate made from a first material,
which may include a thermoplastic polymer such as a thermoplastic
olefin, e.g. polypropylene, or polycarbonate/acrylonitrile
butadiene styrene. A cover is integrally molded to at least a
portion of the substrate and is composed of a second foamed
material. The second foamed material may be a foamed thermoplastic
polymer including a foamed thermoplastic elastomer or foamed
polypropylene such as to provide a soft-feel. The foamed material
generally produces a lightweight cover that includes an outer skin
and a cellular inner core such that the outer skin deforms and
compresses the inner core when a force is applied thereby providing
a soft feel to the trim part. The second foamed material is
activated, or foamed, by a blowing agent, such as sodium
bicarbonate, nitrogen, or any other commonly known blowing
agent.
[0008] An applique, or decorative cut-out, is provided, i.e.
integrated, within a portion of the cover such that the cover is
integrally molded to at least a portion of the applique to retain
the applique. The applique creates a more aesthetically pleasing
trim part, and includes a decorative material such as a textile or
fabric like material including a woven cloth, vinyl, and/or
leather, a plastic material, a metal piece, and the like. The
applique further may be provided with a symbol(s) such as a
letter(s), number(s), word(s), logo(s), picture(s), and the
like.
[0009] The automotive trim part, e.g. a bolster, with integrated
applique is formed in a continuous two-shot molding process. In
this operation, a mold assembly is provided in which the substrate
is formed by injecting the first material into a first shot mold
cavity in a first shot of the molding operation. A core of the mold
assembly is used, advantageously rotated, to move the substrate
from the first shot mold cavity to a second shot mold cavity. The
applique is provided within a portion of the second shot mold
cavity then a mold chamber is formed about at least a portion of
the substrate and the applique within the second shot mold
cavity.
[0010] The cover then is integrally molded intermediate the
substrate and applique by injecting into the mold chamber the
second foamed material in a second shot of the molding operation,
the cover being molded to at least a portion of the substrate and
the applique to form the trim part with integrated applique. In
addition, the foamed second material advantageously generally
provides the trim part with a soft feel. In an exemplary method,
the mold assembly for forming the trim part with applique includes
first and second shot mold cavities and a rotatable core having
first and second male portions adapted to mate with each cavity for
forming a plurality thereof in a continuous manner.
[0011] By virtue of the foregoing, there is thus provided an
improved trim part, such as a bolster, with an integrated applique,
and a method of making the same, that reduces the number of parts
and the labor required for assembly thereof thereby reducing
overall manufacturing costs.
[0012] The features and objectives of the present invention will
become more readily apparent from the following Detailed
Description taken in conjunction with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The accompanying drawings, which are incorporated in and
constitute a part of this specification, illustrate embodiments of
the invention and, together with a general description of the
invention given above, and the detailed description given below,
serve to explain the invention.
[0014] FIG. 1 is a perspective view of an automotive interior trim
assembly including a trim part with applique according to the
present invention;
[0015] FIG. 1A is a cross-sectional view of FIG. 1 taken along the
lines 1A-1A;
[0016] FIG. 1B is a perspective view with a partial cut-away
section of an another embodiment of the automotive interior trim
part with applique according to the present invention;
[0017] FIG. 2 is a perspective view of a mold assembly used to form
the trim part with applique of FIG. 1;
[0018] FIG. 2A is a cross-sectional view of the mold of FIG. 2
taken along the line 2A-2A illustrating the first shot of the
molding operation of the trim part;
[0019] FIG. 3 is a perspective view of the mold assembly of FIG. 2
depicting the rotational movement from the first shot mold cavity
to the second shot mold cavity of the formed substrate of FIG. 2A;
and
[0020] FIG. 3A is a cross-sectional view of the mold of FIG. 3
taken along the line 3A-3A illustrating the second shot of the
molding operation of the trim part.
DETAILED DESCRIPTION OF THE DRAWINGS
[0021] In FIG. 1, an automotive interior trim assembly, i.e. a door
trim panel assembly 8, for an automobile (not shown) includes an
exemplary embodiment of the trim part, i.e. a bolster 12, with
integrated applique 14. It should be understood that the trim part
12 with integrated applique 14 can include any desired automotive
trim part, such as an instrument trim panel, door trim panel,
console panel, armrest, handle, trim plate, airbag cover, etc.,
with each generally being constructed in a similar fashion. Thus,
while the following detailed description focuses primarily on the
bolster 12 with integrated applique 14, those having ordinary skill
in the art will recognize that other trim parts having integrated
appliques may equally be considered for use in any desired trim
assembly.
[0022] With continuing reference to FIG. 1, a door trim panel 10 of
the trim panel assembly 8 covers a portion of the interior of the
automobile (not shown) and includes the bolster 12 with integrated
applique 14 to provide a more aesthetically pleasing environment.
The door panel 10 further includes an armrest 15 with a handle
portion 16 configured for grasping by a vehicle occupant to
facilitate, for example, closing of a car door 18. A variety of
openings, additionally, can be included in the trim panel 10 so as
to accommodate the placement of hardware components 20 such as a
speaker(s), door handle, window controls, etc.
[0023] As best shown in FIGS. 1 and 1A, the bolster 12 defines an
integrated, unitary structure and includes a substrate 24 made from
a first material 26. The first material 26 may include a
thermoplastic polymer such as a thermoplastic olefin, e.g.
polypropylene, or polycarbonate/acrylonitrile butadiene styrene.
Notably, the thickness of the substrate advantageously is about 1-5
mm, more advantageously about 2-4 mm, most advantageously about 3
mm.
[0024] A cover 28 is integrally molded to at least a portion of the
substrate 24 and is made from a second foamed material 30. It
should be understood that the cover 28 may be provided over the
entire substrate 24 or any portion thereof. The second foamed
material 30 may be a foamed thermoplastic polymer including a
foamed thermoplastic elastomer or foamed polypropylene such as to
provide a soft-feel. The second foamed material 30 may be
activated, or foamed, by a blowing agent, such as sodium
bicarbonate and the like, any gas such as nitrogen, or any other
commonly known blowing agent. More specifically, the blowing agent
is combined, or mixed, with a thermoplastic polymer, such as a
thermoplastic elastomer or polypropylene, advantageously a
thermoplastic elastomer available from Kraiburg TPE, Corp. of
Duluth, Ga., to produce the second foamed material 30. The blowing
agent advantageously is present in an amount from 0.1% to 5% by
weight of the mixture, more advantageously from 0.5% to 3% by
weight.
[0025] The foamed material 30 produces the cover 28 which includes
an outer skin 34 and a cellular inner core 36 such that the outer
skin 34 deforms and compresses the inner core 36 when a force is
applied thereby advantageously providing a soft feel to the trim
part 12. Notably, the feel of the cover 28 may be varied, or
adjusted, to any desired softness by changing the thickness
thereof. At a thickness of about 1.5 mm or less, the cover 28
defines an outer skin 34 but is substantially devoid of a soft
inner core 36 because of an inability of the core 36 to be foamed.
As such, the thickness of the cover 28 advantageously is about 5-12
mm, more advantageously about 7-9 mm, and most advantageously about
8 mm.
[0026] An applique 14, or cut-out decoration, is provided, i.e.
integrated, within a portion of the cover 28 such that the cover 28
is integrally molded to at least a portion of the applique 14 to
retain the applique 14. The applique 14 includes a decorative
material such as a textile or fabric like material including a
woven cloth, vinyl, and/or leather, a plastic material, a metal
piece, and the like, and creates a more aesthetically pleasing trim
part 12 for the vehicle driver or occupant. The applique 14 further
may be provided with a symbol(s) 38 (See FIG. 1B) such as a
letter(s), number(s), word(s), logo(s), picture(s), and the like.
The applique 14, as shown in FIG. 1, includes a woven cloth
material.
[0027] Referring further to FIGS. 1 and 1A, the bolster 12 with
integrated applique 14 is formed separately from the door trim
panel 10 and secured thereto by means (not shown) commonly known in
the art, such as by an adhesive, screws, clips, tacks, male
portions, and the like. As such, the bolster 12 can be permanently
secured or removably attached to the door trim panel 10 and may
cover an access opening (not shown) defined therein such that when
the bolster 12 is removed, a technician or assembly line worker can
access the space behind the trim panel 10 to install or service
door components and their drive mechanisms. In other cases, the
trim part, i.e. the bolster 12, may be integrally molded to the
door trim panel 10 and, more specifically, the substrate 24 and/or
cover 28 of the bolster may be integrated, i.e. integrally molded,
within the door panel 10 to provide an integrated bolster 12 with
integrated applique 14.
[0028] In another embodiment, as best shown in FIG. 1B, the trim
part 12 generally may be a trim plate 12a with integrated applique
14. Accordingly, the trim plate 12a with integrated applique 14
similarly defines an integrated, unitary structure and includes the
substrate 24 made from the first material 26, the integrally molded
cover 28 made from the second foamed material 30, and the
integrated applique 14, which is shown including a metal piece
provided with a symbol 38 thereon. The trim plate 12a further is
shown as having been formed separately by the methods further
described below, and can be attached by means commonly known in the
art, such as by an adhesive, to any desired trim part such as a
bolster, armrest, airbag cover, door panel, console panel, etc., to
provide a decorative look.
[0029] With reference to FIGS. 2-3A, a method of making the
automotive trim part, i.e. the bolster 12, with applique 14 of the
present invention will now be described. As best shown in FIG. 2, a
single mold assembly 42 includes spaced apart first and second shot
mold cavities 44 and 46 and a central core 48 having first and
second male portions 50 and 52 adapted to mate with each cavity 44,
46. The core is 48 situated between the mold cavities 44, 46 and is
adapted to rotate about a central axis, i.e. a horizontal axis 56,
so that the first and second male portions 50, 52 can mate, in
turn, with the mold cavities 44, 46 to mold, in sequence, first the
substrate 24 then the cover 28 with integrated applique 14 in a
continuous manner.
[0030] It should be understood by the artisan that variations of
the mold assembly 42 may be provided and still fall within the
scope of this invention. For example, any number of core male
portions 50, 52 (i.e. more or less than shown) may be provided, in
conjunction with the necessary number of corresponding first and
second shot mold cavities 44, 46, for molding the trim part 12 with
integrated applique 14.
[0031] While the first and second shots of the molding operation
are further described below with respect to the first male portion
50 by utilizing the cross-sectional views of FIGS. 2 and 3, it is
understood that the first and second shot molding process occurs in
the same fashion with respect to the second male portion 52.
Accordingly, as best shown in FIGS. 2 and 2A, the first male
portion 50 of the core 48 mates with the first shot mold cavity 44
and, more specifically, the first shot mold cavity 44 is adapted to
move toward the first male portion 50, as is commonly known in the
art, to form a first shot chamber 60.
[0032] In a first shot of the molding operation, the first material
26, which may be a thermoplastic polymer such as a thermoplastic
olefin, e.g. polypropylene, or polycarbonate/acrylonitrile
butadiene styrene, is injected through a channel 62 into the
chamber 60 to form the substrate 24 of the bolster 12.
Specifically, the substrate 24 is molded over the first male
portion 50 such that the first male portion 50 retains the molded
substrate 24. Notably, the thickness of the substrate
advantageously is about 1-5 mm, more advantageously about 2-4 mm,
most advantageously about 3 mm.
[0033] With further reference to FIGS. 3 and 3A, the first shot
mold cavity 44 is retracted, or moved away from, the first male
portion 50, and the core 48 having the first male portion 50
provided with the substrate 24 then is rotated about the horizontal
axis 56 to move the substrate 24 from the first shot mold cavity 44
to the second shot mold cavity 46. It should be understood that the
core 48 also may rotate about a vertical axis or be adapted to
move, or slide, sideways to the second shot mold cavity 46.
[0034] The second shot mold cavity 46 includes a placement area 63
(FIG. 2) adapted to receive and retain the applique 14 in
anticipation of a second shot of the molding operation wherein the
cover 28 for the trim part 12 is molded. Notably, the placement
area 63 includes a recess that is defined by four walls 64 (FIG. 2)
and further is configured to receive the applique 14. The walls 64
of the placement area 63 help retain the applique 14 therein. For
certain appliques 14, such as certain textile or fabric like
materials including woven cloth, that lack the structural support
to be retained within the placement area 63, one or more vacuum
holes 65 can be provided therein. Accordingly, the vacuum holes 65
are connected to a vacuum (not shown), as is known in the art, for
holding the applique 14 in place for the second shot of the molding
operation.
[0035] The depth of the placement area 63 may be adjusted according
to the thickness of the applique 14 and/or according to the desired
depth of integration within the cover 28. In view thereof, the
placement area 63 may be defined by an even, or a raised, surface
(not shown). In addition, the placement area 63 may be defined by
nibs (not shown), or ribs (not shown), configured and adapted to
receive and retain the applique 14. It is further understood that
various combinations of the aforementioned may be utilized for
receiving and retaining the applique 14.
[0036] Accordingly, with further reference to FIGS. 3 and 3A, the
applique 14 is placed within the placement area 63 (FIG. 2) by
means (not shown) commonly known in the art, e.g. manually or
robotically. Next, the first male portion 50 of the core 48 mates
with the second shot mold cavity 46 and, more specifically, the
second shot mold cavity 46 is adapted to move toward the first male
portion 50, as is commonly known in the art, to form a second shot
chamber 66 about at least a portion of the substrate 24 and the
applique 14.
[0037] In the second shot of the molding operation, the second
foamed material 30, which may be a foamed thermoplastic polymer
such as a foamed thermoplastic elastomer or foamed polypropylene,
is injected through a channel 70 into the second shot chamber 66 to
form the cover 28. As best shown in FIG. 3A, the cover 28 is molded
intermediate the substrate 24 and applique 14 so that the cover 28
integrally molds to at least the portion of the substrate 24 and
the applique 14 to form the trim part 12 with integrated applique
14. As indicated above, the second foamed material 30 is activated,
or foamed, by a blowing agent that can include sodium bicarbonate
and the like, any gas such as nitrogen, or any other known blowing
agent. More specifically, the blowing agent is combined, or
pre-mixed, with a thermoplastic polymer, such as a thermoplastic
elastomer or polypropylene, to form the second foamed material
30.
[0038] The foamed material 30 produces the cover 28, which
advantageously includes an outer skin 34 and a cellular inner core
36 such that the outer skin 34 will deform and compress the inner
core 36 when a force is applied thereby providing a soft feel. The
feel of the cover 14 may be varied, or adjusted, to any desired
softness by changing the thickness thereof, such as by altering the
depth of the second shot chamber 66. At a thickness of about 1.5 mm
and less, the cover defines an outer skin 34 but is substantially
devoid of a soft inner core 36 because of an inability of the core
36 to be foamed. As such, the thickness of the cover advantageously
is about 5-12 mm, more advantageously about 7-9 mm, and most
advantageously about 8 mm.
[0039] After the second foamed material 30 has been allowed time
sufficient to cure, the second shot mold cavity 46 is retracted, or
moved away from, the first male portion 50, and the trim part, i.e.
bolster 12, with integrated applique 14 is ejected from the first
male portion 50, such as by ejector pins (not shown), so that the
process may begin anew.
[0040] Although not illustrated, it is understood that the second
male portion 52 also is adapted to mate with the first shot cavity
44, during the mating of the first male portion 50 with the second
shot mold cavity 46, to form a second substrate (not shown) that
may be identical to the first substrate 24 by injecting the first
material 26 into the first shot mold cavity 44 in the first shot of
the molding operation. After injection, the core 48 with the second
male portion 52 similarly rotates the second substrate to the
second shot mold cavity 46 for the second shot of the molding
operation while the first male portion 50 returns to the first shot
mold cavity 44 to repeat the first shot of the molding operation.
In this fashion, a plurality of automotive trim parts 12 with
integrated applique 10 may be formed in a continuous and efficient
manner.
[0041] With further reference to FIGS. 1 and 3A, the molded bolster
12 includes the substrate 24, the cover 28 integrally molded
thereto, and the applique 14 integrated within the cover 28, i.e.
the cover 28 integrally molded to the applique 14. The bolster 12
with integrated applique 14 now may be coupled, by means known in
the art, to the door trim panel 10 for use in a trim assembly 8.
Accordingly, the molding operation of the present invention may be
continuously performed utilizing a single mold assembly 42 to
provide an improved trim part, i.e. a bolster 12, with integrated
applique 14.
[0042] Although, the method of making utilizes a single mold
assembly 42 for a continuous, integrated process, it still should
be understood that the molding process may be performed in more
than one mold assembly such that the substrate 24 may be moved from
the first shot mold cavity 44 after the first shot to a second shot
mold cavity 46 provided in a second, separate mold assembly (not
shown) for the second shot of the molding operation. Movement can
be manually or by other means commonly known in the art, e.g.
robotically.
[0043] While the present invention has been illustrated by the
description of the various embodiments thereof, and while the
embodiments have been described in considerable detail, it is not
intended to restrict or in any way limit the scope of the appended
claims to such detail. Additional advantages and modifications will
readily appear to those skilled in the art. The invention in its
broader aspects is therefore not limited to the specific details,
representative apparatus and methods and illustrative examples
shown and described. Accordingly, departures may be made from such
details without departing from the scope or spirit of Applicant's
general inventive concept.
* * * * *