U.S. patent application number 12/255023 was filed with the patent office on 2009-02-26 for automotive armrest with soft feel and method of making the same.
This patent application is currently assigned to International Automotive Components Group North America, Inc.. Invention is credited to Glenn A. Cowelchuk, Todd L. DePue, David Dooley, Michael J. Hier, Randy S. Reed.
Application Number | 20090051066 12/255023 |
Document ID | / |
Family ID | 35451812 |
Filed Date | 2009-02-26 |
United States Patent
Application |
20090051066 |
Kind Code |
A1 |
Cowelchuk; Glenn A. ; et
al. |
February 26, 2009 |
AUTOMOTIVE ARMREST WITH SOFT FEEL AND METHOD OF MAKING THE SAME
Abstract
The present invention provides for an improved armrest with a
soft feel for use in a trim assembly, and to a continuous two-shot
molding operation that may be continuously performed utilizing a
single mold assembly. In an exemplary embodiment, a trim assembly
includes an integrated armrest formed by injecting a first material
into a first shot mold cavity in a first shot of a molding
operation. An armrest cover is molded to at least a portion of the
armrest by injecting into a mold chamber a second foamed material
in a second shot of the molding operation to provide the armrest
with a soft feel. The second foamed material includes a foamed
material that produces a soft, outer skin and a light, cellular
inner core such that when a force is applied to the cover, the skin
will deform and compress the inner core, providing a soft-touch
feel to the armrest.
Inventors: |
Cowelchuk; Glenn A.;
(Chesterfield Township, MI) ; DePue; Todd L.;
(Brighton, MI) ; Dooley; David; (Troy, MI)
; Hier; Michael J.; (Royal Oak, MI) ; Reed; Randy
S.; (Fair Haven, MI) |
Correspondence
Address: |
WOOD, HERRON & EVANS, LLP
2700 CAREW TOWER, 441 VINE STREET
CINCINNATI
OH
45202
US
|
Assignee: |
International Automotive Components
Group North America, Inc.
Dearborn
MI
|
Family ID: |
35451812 |
Appl. No.: |
12/255023 |
Filed: |
October 21, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10904008 |
Oct 19, 2004 |
7458631 |
|
|
12255023 |
|
|
|
|
Current U.S.
Class: |
264/46.5 |
Current CPC
Class: |
B29C 44/086 20130101;
B60N 2/78 20180201 |
Class at
Publication: |
264/46.5 |
International
Class: |
B29C 65/70 20060101
B29C065/70 |
Claims
1. A method of forming an automotive armrest with soft feel in a:
continuous two-shot molding operation, comprising: providing a mold
assembly having first and second shot mold cavities; molding an
armrest by injecting a first material into the first shot mold
cavity of the mold assembly in a first shot of the molding
operation; moving the armrest 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
armrest within the second shot mold cavity of the mold assembly;
and molding an armrest cover by injecting into the mold chamber a
second foamed material in a second shot of the molding operation,
the cover being molded to the at least a portion of the armrest to
provide the armrest with a soft feel.
2. The method of claim 1, wherein the step of molding an armrest
comprises molding a substrate having an integrated armrest by
injecting the first material in the first shot of the molding
operation, and wherein the step of moving the armrest comprises
moving the substrate having the integrated armrest from the first
shot mold cavity to the second shot mold cavity by using the at
least a portion of the mold assembly to mold the cover to the at
least a portion of the armrest to provide the armrest with the soft
feel.
3. The method of claim 2, wherein the step of molding the substrate
having an integrated armrest comprises molding a door trim panel
having the integrated armrest.
4. The method of claim 1, wherein the first material includes a
thermoplastic polymer and the second foamed material includes a
foamed thermoplastic polymer.
5. The method of claim 4, wherein the foamed thermoplastic polymer
includes one of a foamed thermoplastic elastomer and foamed
polypropylene.
6. The method of claim 1, 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 an armrest comprises molding the
armrest 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 armrest from the first shot mold cavity to the
second shot mold cavity by using at least a portion of the mold
assembly comprises rotating the armrest 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 the at least a portion of the
armrest 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 armrest cover in the second shot of the molding
operation.
7. The method of claim 6, wherein the step of rotating the armrest
comprises rotating the armrest about a horizontal axis to move the
armrest from the first mold cavity to the second mold cavity.
8. A method of forming an automotive armrest with soft feel in a
continuous two-shot molding operation, comprising: molding an
armrest by injecting a first material in a first shot of the
molding operation; forming a mold chamber about at least a portion
of the armrest; and molding an armrest cover by injecting into the
mold chamber a second foamed material in a second shot of the
molding operation, the cover being molded to the at least a portion
of the armrest to provide the armrest with a soft feel.
9. The method of claim 8, wherein the first material includes a
thermoplastic polymer and the second foamed material includes a
foamed thermoplastic polymer.
10. The method of claim 9, wherein the foamed thermoplastic polymer
includes one of a foamed thermoplastic elastomer and foamed
polypropylene.
11. The method of claim 8, wherein the step of molding an armrest
comprises molding a substrate having an integrated armrest by
injecting the first material in the first shot of the molding
operation.
12. The method of claim 11, wherein the step of molding the
substrate having the integrated armrest comprises molding a door
trim panel having the integrated armrest.
Description
[0001] This application is a divisional of U.S. Ser. No. 10/904,008
filed on Oct. 19, 2004 (pending), the disclosure of which is hereby
fully incorporated by reference herein.
[0002] The present invention is also related to U.S. Ser. No.
10/708,312, filed Feb. 24, 2004 (abandoned); U.S. Ser. No.
10/708,315, filed Feb. 24, 2004 (abandoned); U.S. Ser. No.
10/708,500, filed Mar. 8, 2004 (now U.S. Pat. No. 7,070,221); U.S.
Ser. No. 10/709,382, filed Apr. 30, 2004 (pending); U.S. Ser. No.
10/710,305, filed Jul. 1, 2004 (now U.S. Pat. No. 7,104,590); U.S.
Ser. No. 10/904,007, filed Oct. 19, 2004 (now U.S. Pat. No.
7,156,437); U.S. Ser. No. 10/904,010, filed Oct. 19, 2004
(pending); U.S. Ser. No. 10/904,011, filed Oct. 19, 2004 (pending);
U.S. Ser. No. 10/904,015, filed Oct. 19, 2004 (abandoned); U.S.
Ser. No. 10/904,032, filed Oct. 20, 2004 (pending); U.S. Ser. No.
10/711,692, filed Sep. 30, 2004 (abandoned); U.S. Ser. No.
10/904,033, filed Oct. 20, 2004 (pending); U.S. Ser. No.
10/904,408, filed Nov. 9, 2004 (pending); U.S. Ser. No. 10/904,407,
filed Nov. 9, 2004 (pending); U.S. Ser. No. 10/904,433, filed Nov.
10, 2004 (now U.S. Pat. No. 7,192,074); and U.S. Ser. No.
10/904,409, filed Nov. 9, 2004 (now U.S. Pat. No. 7,108,312).
FIELD OF THE INVENTION
[0003] The present invention pertains generally to trim assemblies
for automotive interiors and, more particularly, to automotive
armrests with a soft feel for use in trim assemblies, and to a
method of making the same.
BACKGROUND OF THE INVENTION
[0004] It is known to provide automotive interiors with various
trim assemblies to enhance the aesthetic appearance of the
automotive interior and to provide comfort, as well as convenience,
to vehicle occupants. Examples of these interior trim assemblies
include instrument panels, door panels, and consoles. To increase
the aesthetic appearance of the trim assemblies and to improve the
comfort to vehicle occupants, it is often desired to provide at
least portions, such as the armrests, of the trim assemblies with
areas that are cushy or soft to the touch.
[0005] One primary drawback with current armrests is in the
manufacturing and assembly thereof. Armrests having a soft feel,
typically, have been formed by insertion of a resilient soft
padding material beneath a pliable surface layer of leather, vinyl,
or fabric material. The preformed, soft, 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 trim assembly
with soft feel armrest. In another conventional method of forming
trim assemblies with padded armrests, a foam material may be
injected between a rigid substrate and a skin layer joined to the
substrate.
[0006] In addition, skin layers having bumps or nibs formed on the
B-side, or back surface, thereof have been applied over rigid
substrates in an effort to improve the feel of non-padded armrests.
The nibs raise the skin layer slightly away from the rigid
substrate to create "soft" areas that deform when a force is
applied to the trim assembly. As such, it is the nib design, not
the skin layer per se, that provides these soft areas. Also, while
these nibbed trim assemblies offer a compromise between padded trim
assemblies, they are still costly due to the fact that the skin
layer must be manufactured separately in order to create the bumps
or nibs. Consequently, the above noted methods are generally costly
due to the multiple components and manufacturing steps required to
make these trim assemblies.
[0007] There is thus a need for an improved armrest with a soft
feel 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
[0008] The present invention provides for an improved armrest with
a soft feel for use in a trim assembly, e.g. a door trim panel or
console panel.
[0009] To this end, the trim assembly includes a substrate
including an armrest, advantageously an integrated armrest. The
armrest can be made from a first material that may include a
thermoplastic polymer such as a thermoplastic olefin, e.g.
polypropylene, or polycarbonate/acrylonitrile butadiene styrene. An
armrest cover is integrally molded to at least a portion of the
armrest and is composed of a second foamed material to provide an
armrest having a soft, cushy feel for a user, such as a vehicle
driver or occupant. The second foamed material may be a foamed
thermoplastic polymer such as a foamed thermoplastic elastomer or
foamed polypropylene. The foamed material produces a lightweight
cover that includes an outer skin and a cellular inner core such
that when a force is applied to the cover, the outer skin will
deform and compress the inner core, providing a soft-touch feel to
the armrest. The second foamed material is activated, or foamed, by
a blowing agent, such as sodium bicarbonate, nitrogen, or any other
commonly known blowing agent.
[0010] The automotive armrest with soft feel is formed in a
continuous two-shot molding process. In this operation, a mold
assembly is provided in which the armrest, advantageously a door
trim panel having an integrated armrest, 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 armrest from the first shot
mold cavity to a second shot mold cavity, and a mold chamber is
formed about at least a portion of the armrest within the second
shot mold cavity. The lightweight armrest cover then is integrally
molded thereover by injecting into the mold chamber the second
foamed material in a second shot of the molding operation, the
cover being molded to the portion of the armrest to provide the
armrest with a soft feel. In an exemplary embodiment, the mold
assembly for forming the armrest with soft feel 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 armrest with a soft feel for use in a trim assembly, 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 having an armrest with soft feel according to the present
invention;
[0015] FIG. 2 is a perspective view of a mold assembly used to form
the armrest with soft feel of the present invention;
[0016] 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;
[0017] FIG. 3 is a perspective view of the mold assembly of FIG. 2
depicting the movement from the first shot mold cavity to the
second shot mold cavity of the formed armrest of FIG. 2A;
[0018] 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; and
[0019] FIG. 4 is a cross-sectional view of the formed armrest with
soft feel of FIG. 3A removed from the mold.
DETAILED DESCRIPTION OF THE DRAWINGS
[0020] In FIG. 1, an embodiment of an automotive interior trim
assembly, i.e. a door trim panel 10, for an automobile (not shown)
includes an integrated armrest 12 with soft feel. It should be
understood that the armrest 12 with soft feel, although illustrated
and described herein below as being integrated, may be molded by
the methods disclosed below and provided as a separate part for
attachment to the door trim panel 10. In addition, other various
trim assemblies incorporating armrests, such as consoles, generally
may be constructed in a similar fashion. Thus, while the following
detailed description focuses on the door trim panel 10 having the
integrated armrest 12 with soft feel, those having ordinary skill
in the art will recognize that the armrest 12 with soft feel may
equally be incorporated in other automotive trim assemblies.
[0021] With continuing reference to FIG. 1, the door trim panel 10
covers a portion of the interior of the automobile to provide a
more aesthetically pleasing environment. Notably, the soft feel of
the armrest 12 provides added comfort to the vehicle's occupants
such as when the occupant chooses to rest an arm thereon. In
addition, the armrest 12 further may include 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.
[0022] With continued reference to FIGS. 1 and 4, the door panel 10
includes a substrate 24 provided with the integrated armrest 12
that is 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. The armrest 12 includes an armrest cover 28 that is
bonded, i.e. integrally molded, to at least a portion thereof to
provide the soft, cushy feel for a vehicle driver or occupant. It
should be understood that the cover 28 may be provided over the
entire armrest 12, as well as a portion of the armrest 12 that is
more or less than shown, to provide the armrest 12 with a soft
feel. In addition, as indicated above, the armrest 12 with molded
cover 28 may be provided as a separate part from the door panel 10
for attachment thereto.
[0023] Notably, the cover 28 is composed of a second foamed
material 30 that may include a foamed thermoplastic polymer such as
a foamed thermoplastic elastomer or foamed polypropylene. The
foamed material 30 produces an outer skin 34 and a light, cellular
inner core 36 such that when a force is applied to the cover 28,
the skin 34 will deform and compress the inner core 36, providing a
soft-touch feel to the armrest 12. 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. The feel of the armrest 12 may also be selectively tuned to
a desired softness by varying the thickness of the cover 28.
[0024] With reference to FIGS. 2-3A, a method of making the
automotive armrest 12 with soft-feel of the present invention will
now be described. A single mold assembly 42 is shown in FIG. 2
including 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 armrest 12,
advantageously the substrate 24, such as the door trim panel 10,
with integrated armrest 12, then the armrest cover 28 in a
continuous manner. 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 armrest
12 with soft feel.
[0025] 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.
[0026] 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 having the integrated armrest
12. Specifically, the molded substrate 24 is molded over the first
male portion 50 such that the first male portion 50 retains the
substrate 24. It should be understood, as indicated above, that the
armrest 12 may be molded by the methods disclosed herein as a
separate part for later attachment to the door panel 10, or any
other desired trim assembly, e.g. a console panel. A movable slide
64, as known in the art, is provided within the first shot mold
cavity 44 to produce the handle 16, or pull-cup, portion for
grasping by a vehicle occupant to facilitate the closing of the
vehicle door 18. In addition, a variety of openings may be formed
therein, by means known in the art, so as to accommodate the
placement of hardware components 20 such as a speaker(s), door
handle, window controls, etc.
[0027] 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 a second shot mold cavity. 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 integrated armrest 12.
[0028] In a 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
armrest cover 28. Notably, the cover 28 is bonded, or integrally
molded, to at least the portion of the armrest 12 to provide the
armrest 12 with a soft feel. 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.
[0029] The second foamed material 30 produces the cover 28, which
advantageously includes an outer skin 34 and a light, cellular
inner core 36 such that when a force is applied to the cover 28,
the skin 34 will deform and compress the inner core 36, providing
the soft-touch feel to the armrest 12. In addition, the feel of the
armrest 12 may be adjusted to any desired softness by varying the
thickness of the cover 28, such as by altering the depth of the
second shot chamber 66.
[0030] 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 automotive
interior trim assembly, i.e. the door trim panel 10, having the
integrated armrest 12 with soft feel is ejected from the first male
portion 50, such as by ejector pins (not shown), so that the
process may begin anew. 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 interior trim assemblies having integrated armrests with
soft feel may be formed in a continuous and efficient manner.
[0031] With further reference to FIGS. 1 and 4, the molded trim
panel assembly 10 includes the substrate 24 with integrated armrest
12 and the cover 28 integrally molded thereto thereby forming the
armrest 12 with soft feel. The trim assembly 10 now may be coupled,
by means known in the art, to a doorframe 76 structure of a motor
vehicle. Accordingly, the molding operation of the present
invention may be continuously performed utilizing a single mold
assembly 42 to provide an improved trim assembly 10 having an
armrest 12 with a soft feel.
[0032] Although, the method of making utilizes a single mold
assembly 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 trim part may be moved from the
first shot mold cavity after the first shot to a second shot mold
cavity provided in a second, separate mold assembly for the second
shot of the molding operation. Movement can be manually or by other
means commonly known in the art, e.g. robotically.
[0033] 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.
* * * * *