U.S. patent application number 17/115264 was filed with the patent office on 2021-03-25 for vehicle interior component.
The applicant listed for this patent is Shanghai Yanfeng Jinqiao Automotive Trim Systems Co. Ltd.. Invention is credited to Ronald A. BOZIO, Chris J. HARMELINK, Jason Mathew HIPSHIER, David John MCCARTHY, Amit Mukund PATANKAR.
Application Number | 20210086700 17/115264 |
Document ID | / |
Family ID | 1000005260936 |
Filed Date | 2021-03-25 |
View All Diagrams
United States Patent
Application |
20210086700 |
Kind Code |
A1 |
HIPSHIER; Jason Mathew ; et
al. |
March 25, 2021 |
VEHICLE INTERIOR COMPONENT
Abstract
A vehicle interior component is disclosed. A method of making
the component is also disclosed. The component may comprise a base
providing a compartment and a door. An interface between the base
and door may facilitate movement of the door; the interface may
comprise extrusions/projections on the door to engage guides on the
base. The door may comprise a carrier/substrate and cover/cover
layer; the substrate and/or cover may be formed by extrusion. The
carrier/substrate and cover layer may be formed by co-extrusion
and/or be integrally formed. The cover layer may be bonded to the
substrate. The carrier may be formed by extruding a polymer
material. The carrier may comprise a first polymer material; the
cover may comprise a second polymer material. The component may
comprise at least one of a vehicle trim component, console, storage
compartment, arm rest, etc.
Inventors: |
HIPSHIER; Jason Mathew;
(Holland, MI) ; MCCARTHY; David John; (Holland,
MI) ; PATANKAR; Amit Mukund; (Holland, MI) ;
BOZIO; Ronald A.; (Holland, MI) ; HARMELINK; Chris
J.; (Wyoming, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Shanghai Yanfeng Jinqiao Automotive Trim Systems Co. Ltd. |
Novi |
MI |
US |
|
|
Family ID: |
1000005260936 |
Appl. No.: |
17/115264 |
Filed: |
December 8, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16236217 |
Dec 28, 2018 |
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17115264 |
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PCT/US18/39612 |
Jun 26, 2018 |
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16236217 |
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62525515 |
Jun 27, 2017 |
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62525560 |
Jun 27, 2017 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B60R 7/00 20130101; E06B
9/115 20130101; E06B 9/13 20130101; B60N 2/793 20180201; B60R 5/00
20130101; B60R 21/00 20130101; B60R 2011/0094 20130101; E06B
2009/135 20130101; B60R 2011/0007 20130101; B60R 11/00 20130101;
B60R 7/04 20130101 |
International
Class: |
B60R 7/04 20060101
B60R007/04; B60R 5/00 20060101 B60R005/00; B60R 21/00 20060101
B60R021/00; B60R 7/00 20060101 B60R007/00; B60N 2/75 20060101
B60N002/75; B60R 11/00 20060101 B60R011/00; E06B 9/11 20060101
E06B009/11; E06B 9/13 20060101 E06B009/13 |
Claims
1. A method of making a component for a vehicle interior comprising
a base and a door configured for movement relative to the base to
an open position to facilitate access through an opening into a
compartment of the base and a set of projections on the door
configured to engage a set of guides on the base comprising the
step of: forming the door by extrusion of polymer material through
a tool; wherein the door comprises a cover and a carrier configured
to provide the set of projections; and wherein the step of forming
the door comprises extruding a polymer material to form the
carrier.
2. The method of claim 1 wherein the step of forming the door
further comprises bonding the cover to the carrier.
3. The method of claim 1 wherein the step of forming the door
comprises extruding a polymer material to form the cover.
4. The method of claim 1 wherein the component comprises: (a) the
base providing a compartment with an opening; (b) the door
configured for movement relative to the base to an open position to
facilitate access through the opening into the compartment of the
base.
5. The method of claim 4 wherein the component comprises an
interface between the base and the door configured to facilitate
movement of the door relative to the base; wherein the interface
comprises the set of projections on the door configured to engage a
set of guides on the base.
6. The method of claim 4 wherein the set of projections comprises a
set of extrusions.
7. The method of claim 4 wherein the carrier comprises a substrate
and the cover comprises a cover layer.
8. The method of claim 7 wherein the substrate comprises an
extrusion; wherein the cover layer comprises an extrusion.
9. The method of claim 7 wherein the substrate and the cover layer
are formed by co-extrusion.
10. The method claim 7 wherein the cover layer is bonded to the
substrate as the substrate is extruded.
11. The method of claim 7 wherein the substrate and the cover layer
are integrally formed.
12. The method of claim 7 wherein the cover layer is bonded to the
substrate.
13. The method of claim 7 wherein the substrate comprises the set
of projections; wherein the set of projections comprises a first
projection and a second projection; wherein the cover layer couples
the first projection to the second projection.
14. The method of claim 1 wherein the component comprises at least
one of (a) a vehicle trim component; (b) a console; (c) a center
console; (d) a floor console; (e) a storage compartment; (f) an arm
rest.
15. A method of making a component for a vehicle interior
comprising a base and a door configured for movement relative to
the base to an open position to facilitate access through an
opening into a compartment of the base and a set of projections on
the door configured to engage a set of guides on the base
comprising the step of: forming the door by extrusion of polymer
material through a tool; wherein the step of forming the door
comprises extruding a first polymer material to form a carrier and
extruding a second polymer material to form a cover.
16. The method of claim 15 wherein the carrier and the cover are
formed by co-extrusion of the first polymer material and the second
polymer material.
17. The method of claim 15 wherein the carrier comprises a
substrate and the cover comprises a cover layer.
18. The method of claim 17 wherein the substrate comprises the set
of projections; wherein the set of projections comprises a first
projection and a second projection; wherein the cover layer couples
the first projection to the second projection.
19. The method of claim 15 wherein the cover is bonded to the
carrier.
20. The method of claim 15 wherein the component comprises (a) the
base providing a compartment with an opening; (b) the door
configured for movement relative to the base to an open position to
facilitate access through the opening into the compartment of the
base.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a division of U.S. patent
application Ser. No. 16/236,217 titled "VEHICLE INTERIOR COMPONENT"
filed Dec. 28, 2018 which is a continuation of International/PCT
Patent Application No. PCT/US18/39612 titled "VEHICLE INTERIOR
COMPONENT" filed Jun. 26, 2018, which claims the benefit of U.S.
Provisional Patent Application No. 62/525,515 titled "COMPONENT FOR
VEHICLE INTERIOR" filed Jun. 27, 2017 and U.S. Provisional Patent
Application No. 62/525,560 titled "COMPONENT FOR VEHICLE INTERIOR"
filed Jun. 27, 2017.
[0002] The present application claims priority to and incorporates
by reference in full the following patent applications: (a) U.S.
Provisional Patent Application No. 62/525,515 titled "COMPONENT FOR
VEHICLE INTERIOR" filed Jun. 27, 2017; (b) U.S. Provisional Patent
Application No. 62/525,560 titled "COMPONENT FOR VEHICLE INTERIOR"
filed Jun. 27, 2017; (c) International/PCT Patent Application No.
PCT/US18/39612 titled "VEHICLE INTERIOR COMPONENT" filed Jun. 26,
2018; (d) U.S. patent application Ser. No. 16/236,217 titled
"VEHICLE INTERIOR COMPONENT" filed Dec. 28, 2018.
FIELD
[0003] The present invention relates to a vehicle interior
component.
[0004] The present invention also relates to vehicle interior
component in the form of a console providing an improved door for a
compartment.
[0005] The present invention also relates to a method of making a
component for a vehicle interior.
BACKGROUND
[0006] It is known to provide a vehicle interior with a component
such as a console having a compartment with a door configured for
movement relative to the base to an open position to facilitate
access through the opening into the compartment of the base.
[0007] It would be advantageous to provide an improved vehicle
interior component such as a console with a door. It would also be
advantageous to provide a door for a vehicle interior component
configured for improved efficiency of manufacture/production and in
design/use in the vehicle interior component.
SUMMARY
[0008] The present invention relates to a method of making a
component for a vehicle interior comprising a base and a door
configured for movement relative to the base to an open position to
facilitate access through an opening into a compartment of the base
and a set of projections on the door configured to engage a set of
guides on the base comprising the step of forming the door by
extrusion of polymer material through a tool. The door may comprise
a cover and a carrier configured to provide the set of projections;
the step of forming the door may comprise extruding a polymer
material to form the carrier. The step of forming the door may
comprise bonding the cover to the carrier. The step of forming the
door may comprise extruding a polymer material to form the cover.
The component may comprise the base providing a compartment with an
opening and the door configured for movement relative to the base
to an open position to facilitate access through the opening into
the compartment of the base. The component may comprise an
interface between the base and the door configured to facilitate
movement of the door relative to the base; the interface may
comprise the set of projections on the door configured to engage a
set of guides on the base. The set of projections may comprise a
set of extrusions. The carrier may comprise a substrate and the
cover may comprise a cover layer. The substrate may comprise an
extrusion; the cover layer may comprise an extrusion. The substrate
and the cover layer may be formed by co-extrusion. The cover layer
may be bonded to the substrate as the substrate is extruded. The
substrate and cover layer may be integrally formed. The cover layer
may be bonded to the substrate. The substrate may comprise the set
of projections; the set of projections may comprise a first
projection and a second projection; the cover layer may couple the
first projection to the second projection. The component may
comprise at least one of (a) a vehicle trim component; (b) a
console; (c) a center console; (d) a floor console; (e) a storage
compartment; (f) an arm rest.
[0009] The present invention relates to a method of making a
component for a vehicle interior comprising a base and a door
configured for movement relative to the base to an open position to
facilitate access through an opening into a compartment of the base
and a set of projections on the door configured to engage a set of
guides on the base comprising the step of forming the door by
extrusion of polymer material through a tool. The step of forming
the door may comprise extruding a first polymer material to form a
carrier and extruding a second polymer material to form a cover.
The carrier and the cover may be formed by co-extrusion of the
first polymer material and the second polymer material. The carrier
may comprise a substrate and the cover may comprise a cover layer.
The substrate may comprise the set of projections; the set of
projections may comprise a first projection and a second
projection; the cover layer may couple the first projection to the
second projection. The cover may be bonded to the carrier. The
component may comprise the base providing a compartment with an
opening and the door configured for movement relative to the base
to an open position to facilitate access through the opening into
the compartment of the base.
[0010] The present invention relates to a vehicle interior
component. The vehicle interior component may comprise a base
providing a compartment with an opening and a door configured for
movement relative to the base to an open position to facilitate
access through the opening into the compartment of the base; an
interface may be provided between the base and the door configured
to facilitate movement of the door relative to the base; the
interface may comprise a set of projections on the door configured
to engage a set of guides on the base. The set of projections may
comprise a set of extrusions.
[0011] The set of projections may comprise a first projection and a
second projection; the first projection may comprise a cross
section; the cross section of the first projection may be
substantially constant throughout the first projection. The set of
projections may be formed by extrusion. The set of projections may
be formed by extruding a polymer material in a direction
substantially perpendicular to a path of movement of the door
relative to the base. The set of projections may be formed by
extruding a polymer material in a direction substantially parallel
to a path of movement of the door relative to the base. The door
may be formed by extrusion and the set of projections may be formed
by a cutting operation. The door may comprise a set of openings;
the set of projections may be coupled to the door at the set of
openings. The door may comprise a set of channels; the set of
projections may extend through the set of channels. The door may
comprise at least one of a set of apertures or a set of grooves;
the set of projections may be inserted into the at least one of the
set of apertures or the set of grooves. The door may comprise a
substrate and a cover layer.
[0012] The substrate may comprise an extrusion; the cover layer may
comprise an extrusion. The substrate and the cover layer may be
formed by co-extrusion. The cover layer may be bonded to the
substrate as the substrate is extruded. The substrate and cover
layer may be integrally formed. The cover layer may be bonded to
the substrate. The substrate may comprise a cross section; the
cross section of the substrate may be substantially constant. The
substrate may comprise the set of projections; the set of
projections may comprise a first projection and a second
projection; the cover layer may couple the first projection to the
second projection. The substrate may be formed by extrusion. The
substrate may be bonded to the cover layer as the substrate is
extruded.
[0013] The door may be prepared by a process comprising extruding a
material to form an extruded substrate. The process may comprise
the step of removing a portion of the extruded substrate to form
the set of projections.
[0014] The set of projections may comprise at least one of (a) a
set of projections formed on the door; (b) a set of pins formed on
the door; (c) a set of posts formed on the door; (d) a set of
members formed on the door; (e) a set of features formed on the
door; (f) a set of pegs formed on the door; (g) a rim formed on the
door; (h) a support formed on the door; (i) a flange formed on the
door.
[0015] The set of projections may comprise at least one of (a) a
set of projections integrally formed on the door; (b) a set of pins
integrally formed on the door; (c) a set of posts integrally formed
on the door; (d) a set of members integrally formed on the door;
(e) a set of features integrally formed on the door; (f) a set of
pegs integrally formed on the door; (g) a rim integrally formed on
the door; (h) a support integrally formed on the door; (i) a flange
integrally formed on the door.
[0016] The door may comprise a door assembly. The door assembly may
comprise at least one of (a) a cover and a substrate; (b) a cover
and a base; (c) a cover structure and a carrier structure; (d) a
cover and a carrier structure; (e) a base structure comprising a
cover and a substrate comprising the set of projections; (f) a
cover and a base structure formed by co-extrusion; (g) a cover and
a carrier structure formed by co-extrusion; (h) a cover and a
carrier formed by co-extrusion; (i) a cover coupled to a carrier
formed by extrusion.
[0017] The present invention relates to a method of making a
component for a vehicle interior comprising a base and a door
configured for movement relative to the base to an open position to
facilitate access through the opening into a compartment of the
base and a set of projections on the door configured to engage a
set of guides on the base comprising the step of forming the door
by extrusion of polymer material through a tool.
[0018] The door may comprise a cover and a carrier configured to
provide the set of projections. The method may further comprise the
step of forming the set of projections on the carrier. The method
may further comprise the step of attaching the set of projections
to the carrier.
[0019] The step of forming the door may comprise extruding a
polymer material to form a cover. The step of forming the door may
comprise extruding a first polymer material to form a carrier and
extruding a second polymer material to form a cover. The step of
forming the door may comprise extruding the first polymer material
in a first direction to form the carrier and extruding the second
polymer material in a second direction to form the cover. The door
may comprise a cover and a carrier configured to provide the set of
projections; forming the door may comprise extruding a polymer
material to form the carrier. The step of forming the door may
comprise bonding the cover to the carrier.
[0020] The present invention relates to a vehicle interior
component. The vehicle interior component may comprise a base
providing a compartment with an opening and a door configured for
movement relative to the base to an open position to facilitate
access through the opening into the compartment of the base and an
interface between the base and the door configured to facilitate
movement of the door relative to the base The interface may
comprise a set of projections on the door configured to engage a
set of guides on the base; the door may comprise a carrier
configured to provide the set of projections and a cover. The door
may be formed by extrusion. The set of projections may be formed on
the carrier. The carrier may be formed by extrusion of a polymer
material. The cover may be formed by extrusion of a polymer
material. The door may be formed by attachment of the cover to the
carrier. The door may be formed by co-extrusion of the cover and
the carrier. The cover and the carrier may be integrally formed.
The cover may be bonded to the carrier. The set of projections may
be formed by extrusion of the carrier. The set of projections may
be formed by machining of the carrier. The set of projections may
be attached to the carrier.
[0021] The set of projections may comprise at least one of (a) a
set of projections formed on the carrier; (b) a set of pins formed
on the carrier; (c) a set of posts formed on the carrier; (d) a set
of members formed on the carrier; (e) a set of features formed on
the carrier; (f) a set of pegs formed on the carrier; (g) a rim
formed on the carrier; (h) a support formed on the carrier; (i) a
set of supports formed on the carrier; (j) a flange formed on the
carrier; (k) a set of flanges formed on the carrier; (l) a set of
projections attached to the carrier; (m) a set of projections
attached in a set of apertures on the carrier; (n) a set of
projections integrally formed on the carrier; (o) a set of
projections formed by machining of the carrier; (p) a set of
projections comprising a set of features formed by machining of the
carrier.
[0022] The door may comprise a door assembly. The door assembly may
comprise at least one of (a) a cover and a substrate; (b) a cover
and a base; (c) a cover structure and a carrier structure; (d) a
cover and a carrier structure; (e) a base structure comprising a
cover and a substrate comprising the set of projections; (f) a
cover and a base structure formed by co-extrusion; (g) a cover and
a carrier structure formed by co-extrusion; (h) a cover and a
carrier formed by co-extrusion; (i) a cover coupled to a carrier
formed by extrusion.
[0023] The present invention relates to a vehicle trim component.
The component may comprise a base and a cover (e.g. provided by or
as a door, door assembly, etc.) comprising a set of pins configured
to engage the base and facilitate movement of the cover relative to
the base between a closed position and an open position. The cover
(e.g. cover, cover structure/assembly, door, door
structure/assembly, etc.) may comprise a top layer and a bottom
layer; the bottom layer may comprise openings; the set of pins may
be coupled to the bottom layer at the openings. The bottom layer of
the cover may comprise substantially parallel ribs configured to
move relative to one another to facilitate bending of the cover.
The substantially parallel ribs may comprise the openings. The
bottom layer of the cover may comprise notches configured to
facilitate bending of the cover. The bottom layer may comprise
substantially parallel ribs configured to move relative to one
another to facilitate bending of the cover; the notches may be
between the ribs. Each pin of the set of pins may comprise a first
portion configured to couple the set of pins to the openings and a
second portion configured to engage the base. The second portion of
each pin of the set of pins may be substantially spherical. The
base may comprise a first wall and a second wall opposing the first
wall; the set of pins may comprise a first subset of pins and
second subset of pins; the first subset of pins may be configured
to engage the first wall of the base and the second subset of pins
may be configured to engage the second wall of the base. The top
layer and the bottom layer may be prepared by an extrusion process
and the top layer may be bonded to the bottom layer. The top layer
may be comprised of a first material and the bottom layer may be
comprised of a second material different than the first material;
the top layer and the bottom layer may be prepared by an extrusion
process and the top layer may be bonded to the bottom layer. The
top layer may be bonded to the bottom layer as the top layer and
the bottom layer are extruded.
[0024] The present invention also relates to a vehicle trim
component. The component may comprise a base and a cover (e.g.
provided by or as a door, door assembly, etc.) comprising a set of
pins configured to engage the base and facilitate movement of the
cover relative to the base between a closed position and an open
position. The cover (e.g. cover, cover structure/assembly, door,
door structure/assembly, etc.) may comprise a top layer and a
bottom layer; the bottom layer of the cover may comprise the set of
pins. The bottom layer may comprise substantially parallel ribs
configured to move relative to one another to facilitate bending of
the cover. The substantially parallel ribs may comprise
protrusions; the set of pins may be bonded to the protrusions. Each
pin of the set of pins may comprise a first portion configured to
couple the set of pins to the protrusions and a second portion
configured to engage the base. The second portion of each pin of
the set of pins may be substantially spherical. The base may
comprise a first wall and a second wall opposing the first wall;
the set of pins may comprise a first subset of pins and second
subset of pins; the first subset of pins may be configured to
engage the first wall of the base and the second subset of pins may
be configured to engage the second wall of the base. The top layer
and the bottom layer may be prepared by an extrusion process and
the top layer may be bonded to the bottom layer; the top layer may
be comprised of a first material and the bottom layer may be
comprised of a second material different than the first material.
The top layer and the bottom layer may be prepared by an extrusion
process and the top layer may be bonded to the bottom layer; the
top layer may be bonded to the bottom layer as the top layer and
the bottom layer are extruded.
[0025] The present invention also relates to a vehicle trim
component. The component may comprise a base and a cover (e.g.
provided by or as a door, door assembly, etc.) comprising a set of
pins configured to engage the base and facilitate movement of the
cover relative to the base between a closed position and an open
position. The cover (e.g. cover, cover structure/assembly, door,
door structure/assembly, etc.) may comprise a top layer and a
bottom layer; the base may comprise a first wall and a second wall
opposing the first wall; the set of pins may comprise a first
subset of pins and second subset of pins; the first subset of pins
may be configured to engage the first wall of the base and the
second subset of pins may be configured to engage the second wall
of the base. The bottom layer of the cover may comprise
substantially parallel ribs configured to move relative to one
another to facilitate bending of the cover; the set of pins may be
coupled to the substantially parallel ribs. Each pin of the set of
pins may comprise a first portion configured to couple each pin to
the bottom layer of the cover and a second portion configured to
engage the base. The second portion of each pin may be
substantially spherical. The top layer and the bottom layer may be
prepared by an extrusion process and the top layer may be bonded to
the bottom layer. The top layer may be comprised of a first
material and the bottom layer may be comprised of a second material
different than the first material. The top layer and the bottom
layer may be prepared by an extrusion process and the top layer may
be bonded to the bottom layer. The top layer may be bonded to the
bottom layer as the top layer and the bottom layer are
extruded.
[0026] The present invention also relates to a vehicle trim
component. The component may comprise a base and a cover (e.g.
provided by or as a door, door assembly, etc.) comprising a set of
pins configured to engage the base and facilitate movement of the
cover relative to the base between a closed position and an open
position. The cover (e.g. cover, cover structure/assembly, door,
door structure/assembly, etc.) may comprise a top layer and a
bottom layer; the bottom layer may comprise a set of protrusions;
the set of pins may be coupled to the bottom layer at the
protrusions. The bottom layer of the cover may comprise
substantially parallel ribs configured to move relative to one
another to facilitate bending of the cover. The ribs may comprise
the protrusions. Each pin of the set of pins may comprise a first
portion configured to couple the set of pins to the set of
protrusions and a second portion configured to engage the base. The
second portion of each pin of the set of pins may be substantially
spherical. The base may comprise a first wall and a second wall
opposing the first wall; the set of pins may comprise a first
subset of pins and second subset of pins; the first subset of pins
may be configured to engage the first wall of the base and the
second subset of pins may be configured to engage the second wall
of the base. The top layer and the bottom layer may be prepared by
an extrusion process and the top layer may be bonded to the bottom
layer. The top layer may be comprised of a first material and the
bottom layer may be comprised of a second material different than
the first material. The top layer and the bottom layer may be
prepared by an extrusion process and the top layer may be bonded to
the bottom layer; the top layer may be bonded to the bottom layer
as the top layer and the bottom layer are extruded.
[0027] The present invention also relates to a trim component for a
vehicle interior. The component may comprise a base and a cover
(e.g. provided by or as a door, door assembly, etc.) comprising
pins configured to engage the base and facilitate movement of the
cover relative to the base between a closed position and an open
position. The cover (e.g. cover, cover structure/assembly, door,
door structure/assembly, etc.) may comprise a top layer and a
bottom layer bonded to the top layer; the top layer and the bottom
layer may be prepared by an extrusion process. The top layer may be
comprised of a first material and the bottom layer may be comprised
of a second material different than the first material. The top
layer may be bonded to the bottom layer as the top layer and the
bottom layer are extruded.
[0028] The present invention also relates to a vehicle trim
component. The trim component may comprise a base and a cover (e.g.
provided by or as a door, door assembly, etc.) comprising a set of
pins configured to engage the base and facilitate movement of the
cover relative to the base between a closed position and an open
position. The cover (e.g. cover, cover structure/assembly, door,
door structure/assembly, etc.) may comprise a top layer, a first
bottom layer and a second bottom layer; the first bottom layer may
be bonded to the top layer and the second bottom layer may be
bonded to the top layer. The set of pins may comprise a first
subset of pins and a second subset of pins; the first bottom layer
may comprise the first subset of pins and the second bottom layer
may comprise the second subset of pins. The top layer may be
comprised of a first material; the first bottom layer and the
second bottom layer may be comprised of a second material different
than the first material. The top layer, the first bottom layer and
the second bottom layer may be prepared by an extrusion process;
the top layer may be bonded to the first bottom layer and the
second bottom layer as the top layer; the first bottom layer and
the second bottom layer are extruded.
[0029] The present invention also relates to a trim component for a
vehicle interior. The component may comprise a base and a cover
(e.g. provided by or as a door, door assembly, etc.) comprising a
set of pins configured to engage the base and facilitate movement
of the cover relative to the base between a closed position and an
open position. The cover (e.g. cover, cover structure/assembly,
door, door structure/assembly, etc.) may be prepared by a process
comprising extruding a first material to form a bottom layer of the
cover and extruding a second material to form a top layer of the
cover. The process may also comprise removing a portion of at least
one of the bottom layer of the cover or the top layer of the cover
to form the pins. At least one of the first material or the second
material may be extruded in a direction substantially parallel to a
path of movement of the cover. The top layer of the cover may
comprise a top surface configured to face the interior of the
vehicle; the top surface of the top layer of the cover may be
non-planar.
[0030] The present invention also relates to a method of making a
cover (e.g. provided by or as a door, door assembly, etc.) for a
vehicle trim component. The method may comprise extruding a first
polymer material through a first extrusion die in a direction
substantially perpendicular to a direction of travel of the cover
to form a top layer of a cover precursor; extruding a second
polymer material through a second extrusion die in a direction
substantially perpendicular to a direction of travel of the cover
to form a bottom layer of the cover precursor; bonding the top
layer to the bottom layer; and cutting away portions of the cover
precursor to form protrusions. The protrusions may comprise pins
configured to engage a base of the vehicle trim component and
facilitate movement of the cover relative to the base between a
closed position and an open position. The method may also comprise
coupling a mold to the cover precursor over the protrusions and
molding pins over each of the protrusions; the pins may be
configured to engage a base of the vehicle trim component and
facilitate movement of the cover relative to the base between a
closed position and an open position. Extruding the first polymer
material through the first extrusion die may occur simultaneously
with extruding the second polymer through the second extrusion die;
the top layer may be bonded to the bottom layer simultaneously with
extruding the first and second polymer materials.
[0031] The present invention also relates to a method of making a
cover (e.g. provided by or as a door, door assembly, etc.) for a
vehicle trim component. The method may comprise extruding a first
polymer material through a first extrusion die in a direction
substantially perpendicular to a direction of travel of the cover
to form a top layer of a substrate; extruding a second polymer
material through a second extrusion die in a direction
substantially perpendicular to a direction of travel of the cover
to form a bottom layer of a substrate; and bonding the top layer to
the bottom layer. The method may also comprise bonding preformed
pins into channels of the substrate. The pins may extend entirely
through the channels; the pins may extend partially through the
channels. Extruding the first polymer material through the first
extrusion die may occur simultaneously with extruding the second
polymer material through the second extrusion die; the top layer
may be bonded to the bottom layer simultaneously with extruding the
first and second polymer materials. Extruding the second polymer
material through the second extrusion die may be started before
extruding the first polymer material through the first extrusion
die and stopped after extruding the first polymer material through
the first extrusion die has stopped.
[0032] The present invention further relates to a method of making
a cover (e.g. provided by or as a door, door assembly, etc.) for a
vehicle trim component. The method may comprise extruding a first
polymer material through a first extrusion die in a direction
substantially parallel to a direction of travel of the cover to
form a top layer of a substrate; extruding a second polymer
material through a second extrusion die in a direction
substantially parallel to the direction of travel of the cover to
form a top layer of a substrate; bonding the top layer to the
bottom layer; and cutting away portions of the substrate to form
pins configured to engage a base of the vehicle trim component and
facilitate movement of the cover relative to the base between a
closed position and an open position. Extruding the first polymer
material through the first extrusion die may occur simultaneously
with extruding the second polymer through the second extrusion die;
the top layer may be bonded to the bottom layer simultaneously with
extruding the first and second polymer materials.
[0033] The present invention relates to a vehicle trim component.
The component may comprise a base and a cover (e.g. provided by or
as a door, door assembly, etc.) comprising pins configured to
engage the base and facilitate movement of the cover relative to
the base between a closed position and an open position. The cover
(e.g. cover, cover structure/assembly, door, door
structure/assembly, etc.) may comprise a substrate comprising
openings. The pins may be coupled to the substrate at the openings.
The substrate may comprise substantially parallel ribs configured
to move relative to one another to facilitate bending of the cover;
the ribs may comprise the openings. The cover may comprise a
visible surface; the substrate may comprise apertures between the
visible surface and the openings. The substrate may comprise
notches configured to facilitate bending of the cover; the
substrate may comprise substantially parallel ribs configured to
move relative to one another to facilitate bending of the cover.
The notches may be between the ribs. Each of the pins may comprise
a first portion configured to couple each of the pins to the
openings and a second portion configured to engage the base. The
second portion of each of the pins may be substantially spherical.
The base may comprise a first wall and a second wall opposing the
first wall; the pins may comprise a first set of pins and second
set of pins; the first set of pins may be configured to engage the
first wall of the base and the second set of pins may be configured
to engage the second wall of the base. The substrate may comprise a
core comprising a first thickness and an extension comprising a
second thickness less than the first thickness. The base may
comprise a first wall and a second wall opposing the first wall;
the extension may comprise a portion of the pins; the extension may
be configured to engage the base and the core may be configured to
extend between the first wall and the second wall.
[0034] The present invention also relates to a vehicle trim
component. The component may comprises a base and a cover (e.g.
provided by or as a door, door assembly, etc.) comprising pins
configured to engage the base and facilitate movement of the cover
relative to the base between a closed position and an open
position. The cover (e.g. cover, cover structure/assembly, door,
door structure/assembly, etc.) may comprise a substrate. The pins
may be bonded to the substrate. The substrate may comprise
substantially parallel ribs configured to move relative to one
another to facilitate bending of the cover. The ribs may comprise
protrusions; the pins may be bonded to the protrusions. Each of the
pins may comprise a first portion configured to couple each of the
pins to the protrusions and a second portion configured to engage
the base. The second portion of each of the pins may be
substantially spherical. The substrate may comprise notches
configured to facilitate bending of the cover. The substrate may
comprise substantially parallel ribs configured to move relative to
one another to facilitate bending of the cover. The notches may be
between the ribs. The base may comprise a first wall and a second
wall opposing the first wall; the pins may comprise a first set of
pins and second set of pins; the first set of pins may be
configured to engage the first wall of the base and the second set
of pins may be configured to engage the second wall of the base.
The substrate may comprise a core comprising a first thickness and
an extension comprising a second thickness less than the first
thickness. The base may comprise a first wall and a second wall
opposing the first wall; the pins may be bonded to the extension;
the core may be configured to extend between the first wall and the
second wall. The substrate may be prepared by an extrusion process
and the pins may be bonded to the substrate as the pins are
molded.
[0035] The present invention also relates to a vehicle trim
component. The component may comprise a base and a cover (e.g.
provided by or as a door, door assembly, etc.) comprising pins
configured to engage the base and facilitate movement of the cover
relative to the base between a closed position and an open
position. The cover (e.g. cover, cover structure/assembly, door,
door structure/assembly, etc.) may comprise a substrate; the base
may comprise a first wall and a second wall opposing the first
wall; the pins may comprise a first set of pins and second set of
pins; the first set of pins may be configured to engage the first
wall of the base and the second set of pins may be configured to
engage the second wall of the base. The substrate may comprise
substantially parallel ribs configured to move relative to one
another to facilitate bending of the cover; the pins may be coupled
to the ribs. The substrate may comprise notches configured to
facilitate bending of the cover. The substrate may comprise
substantially parallel ribs configured to move relative to one
another to facilitate bending of the cover. The notches may be
between the ribs. Each of the pins of the first set of pins and the
second set of pins may comprise a first portion configured to
couple each of the pins to the substrate and a second portion
configured to engage the base. The second portion of the pins may
be substantially spherical. The substrate may comprise a core
comprising a first thickness and an extension comprising a second
thickness less than the first thickness; the extension may comprise
a portion of the first set of pins and the second set of pins; the
extension may be configured to engage the base and the core may be
configured to extend between the first wall and the second
wall.
[0036] The present invention also relates to a vehicle trim
component. The component may comprise a base and a cover (e.g.
provided by or as a door, door assembly, etc.) comprising pins
configured to engage the base and facilitate movement of the cover
relative to the base between a closed position and an open
position. The cover (e.g. cover, cover structure/assembly, door,
door structure/assembly, etc.) may comprise a substrate comprising
protrusions; the pins may be coupled to the substrate at the
protrusions. The substrate may comprise substantially parallel ribs
configured to move relative to one another to facilitate bending of
the cover. The ribs may comprise the protrusions. The substrate may
comprise notches configured to facilitate bending of the cover. The
substrate may comprise substantially parallel ribs configured to
move relative to one another to facilitate bending of the cover;
the notches may be between the ribs. Each of the pins may comprise
a first portion configured to couple each of the pins to the
protrusions and a second portion configured to engage the base. The
second portion of the pins may be substantially spherical. The base
may comprise a first wall and a second wall opposing the first
wall; the pins may comprise a first set of pins and second set of
pins; the first set of pins may be configured to engage the first
wall of the base and the second set of pins may be configured to
engage the second wall of the base. The substrate may comprise a
core comprising a first thickness and an extension comprising a
second thickness less than the first thickness. The base may
comprise a first wall and a second wall opposing the first wall;
the extension may comprise a portion of the pins; the extension may
be configured to engage the base and the core may be configured to
extend between the first wall and the second wall.
[0037] The present invention also relates to a trim component for a
vehicle interior. The component may comprise a base and a cover
(e.g. provided by or as a door, door assembly, etc.) comprising
pins configured to engage the base and facilitate movement of the
cover relative to the base between a closed position and an open
position. The cover (e.g. cover, cover structure/assembly, door,
door structure/assembly, etc.) may comprise a substrate comprising
a first portion hinged to a second portion; the second portion may
comprise a top surface and the first portion may comprise a bottom
surface. The bottom surface of the first portion of the substrate
may be adjacent the top surface of the second portion of the
substrate. The top surface of the second portion of the substrate
may be bonded to the bottom surface of the first portion of the
substrate. The first portion of the substrate may comprise a top
surface configured to face the interior of the vehicle. The
substrate may be prepared by an extrusion process and the second
portion of the substrate may be folded onto the first portion of
the substrate after the extrusion process to form the cover (e.g.
cover, cover structure/assembly, door, door structure/assembly,
etc.).
[0038] The present invention also relates to a vehicle trim
component. The component may comprise a base and a cover (e.g.
provided by or as a door, door assembly, etc.) comprising pins
configured to engage the base and facilitate movement of the cover
relative to the base between a closed position and an open
position. The cover (e.g. cover, cover structure/assembly, door,
door structure/assembly, etc.) may be prepared by a process
comprising extruding a material to form an extruded substrate and
removing a portion of the extruded substrate to form the pins.
[0039] The present invention also relates to a vehicle trim
component. The component may comprise a base and a cover (e.g.
provided by or as a door, door assembly, etc.) comprising pins
configured to engage the base and facilitate movement of the cover
relative to the base along a path between a closed position and an
open position. The cover (e.g. cover, cover structure/assembly,
door, door structure/assembly, etc.) may comprise a substrate
prepared by an extrusion process; the substrate may be extruded in
a direction substantially parallel to the path of movement of the
cover. The pins may be configured to move relative to one another
to facilitate bending of the cover.
[0040] The present invention also relates to a method of making a
cover (e.g. provided by or as a door, door assembly, etc.) for a
vehicle trim component. The method may comprise extruding a polymer
material through an extrusion die in a direction substantially
perpendicular to a direction of travel of the cover to form a cover
precursor and cutting away portions of the cover precursor to form
protrusions. The protrusions may comprise pins configured to engage
a base of the vehicle trim component and facilitate movement of the
cover relative to the base between a closed position and an open
position. The method may also comprise coupling a mold to the cover
precursor over the protrusions and molding pins over each of the
protrusions; the pins may be configured to engage a base of the
vehicle trim component and facilitate movement of the cover
relative to the base between a closed position and an open
position.
[0041] The present invention also relates to a method of making a
cover (e.g. provided by or as a door, door assembly, etc.) for a
vehicle trim component. The method may comprise extruding a polymer
material through an extrusion die in a direction substantially
perpendicular to a direction of travel of the cover to form a
substrate and bonding preformed pins into channels of the
substrate. The pins may extend entirely through the channels; the
pins may extend partially through the channels. The substrate may
comprise a first portion comprising a top surface hinged to a
second portion comprising a bottom surface. The method may also
comprise bonding the first portion of the substrate to the bottom
surface of the second portion of the substrate.
[0042] The present invention further relates to a method of making
a cover (e.g. provided by or as a door, door assembly, etc.) for a
vehicle trim component. The method may comprise extruding a polymer
material through an extrusion die in a direction substantially
parallel to a direction of travel of the cover to form a substrate;
and cutting away portions of the substrate to form pins configured
to engage a base of the vehicle trim component and facilitate
movement of the cover relative to the base between a closed
position and an open position.
FIGURES
[0043] FIG. 1A is a schematic perspective view of a vehicle
according to an exemplary embodiment.
[0044] FIG. 1B is a schematic perspective cut-away view of a
vehicle showing the interior of the vehicle according to an
exemplary embodiment.
[0045] FIG. 1C is a schematic perspective view of a component of a
vehicle interior according to an exemplary embodiment.
[0046] FIG. 1D is a schematic perspective view of a cover for a
component of a vehicle interior according to an exemplary
embodiment.
[0047] FIGS. 2A to 2C are schematic perspective views of a
component of a vehicle interior with a cover moved between a closed
position and an open position according to an exemplary
embodiment.
[0048] FIG. 2D is a schematic perspective view of a cover for a
component of a vehicle interior according to an exemplary
embodiment.
[0049] FIG. 2E is a schematic section view of a cover for a
component of a vehicle interior engaged with a base of the
component according to an exemplary embodiment.
[0050] FIG. 2F is a schematic partial section view of a cover for a
component of a vehicle interior engaged with a base of the
component according to an exemplary embodiment.
[0051] FIG. 3A is a schematic perspective view of a cover for a
component of a vehicle interior according to an exemplary
embodiment.
[0052] FIG. 3B is a schematic perspective exploded view of a cover
for a component of a vehicle interior according to an exemplary
embodiment.
[0053] FIG. 3C is a schematic side view of a cover for a component
of a vehicle interior according to an exemplary embodiment.
[0054] FIG. 3D is a schematic view of first and second extrusion
dies for forming a cover for a component of a vehicle interior
according to an exemplary embodiment.
[0055] FIG. 3E is a schematic partial perspective view of a cover
precursor for a component of a vehicle interior according to an
exemplary embodiment.
[0056] FIG. 3F is a schematic partial section view of a cover for a
component of a vehicle interior engaged with a base of the
component according to an exemplary embodiment.
[0057] FIG. 3G is a schematic partial perspective view of a cover
for a component of a vehicle interior according to an exemplary
embodiment.
[0058] FIG. 4A is a schematic perspective view of a cover for a
component of a vehicle interior according to an exemplary
embodiment.
[0059] FIG. 4B is a schematic perspective exploded view of a cover
for a component of a vehicle interior according to an exemplary
embodiment.
[0060] FIG. 4C is a schematic side view of a cover for a component
of a vehicle interior according to an exemplary embodiment.
[0061] FIG. 4D is a schematic view of first and second extrusion
dies for forming a cover for a component of a vehicle interior
according to an exemplary embodiment.
[0062] FIG. 4E is a schematic partial perspective view of a cover
precursor for a component of a vehicle interior according to an
exemplary embodiment.
[0063] FIG. 4F is a schematic partial section view of a cover for a
component of a vehicle interior engaged with a base of the
component according to an exemplary embodiment.
[0064] FIG. 4G is a schematic partial perspective view of a cover
for a component of a vehicle interior according to an exemplary
embodiment.
[0065] FIG. 5A is a schematic perspective view of a cover for a
component of a vehicle interior according to an exemplary
embodiment.
[0066] FIG. 5B is a schematic perspective exploded view of a cover
for a component of a vehicle interior according to an exemplary
embodiment.
[0067] FIG. 5C is a schematic side view of a cover for a component
of a vehicle interior according to an exemplary embodiment.
[0068] FIG. 5D is a schematic view of first and second extrusion
dies for forming a cover for a component of a vehicle interior
according to an exemplary embodiment.
[0069] FIG. 5E is a schematic partial perspective view of a cover
precursor for a component of a vehicle interior according to an
exemplary embodiment.
[0070] FIG. 5F is a schematic partial section view of a cover for a
component of a vehicle interior engaged with a base of the
component according to an exemplary embodiment.
[0071] FIG. 6A is a schematic perspective view of a cover for a
component of a vehicle interior according to an exemplary
embodiment.
[0072] FIG. 6B is a schematic perspective exploded view of a cover
for a component of a vehicle interior according to an exemplary
embodiment.
[0073] FIG. 6C is a schematic side view of a cover for a component
of a vehicle interior according to an exemplary embodiment.
[0074] FIG. 6D is a schematic view of first and second extrusion
dies for forming a cover for a component of a vehicle interior
according to an exemplary embodiment.
[0075] FIG. 6E is a schematic partial perspective view of a cover
for a component of a vehicle interior according to an exemplary
embodiment.
[0076] FIG. 6F is a schematic partial section view of a cover for a
component of a vehicle interior engaged with a base of the
component according to an exemplary embodiment.
[0077] FIG. 7A is a schematic perspective view of a cover for a
component of a vehicle interior according to an exemplary
embodiment.
[0078] FIG. 7B is a schematic perspective exploded view of a cover
for a component of a vehicle interior according to an exemplary
embodiment.
[0079] FIG. 7C is a schematic side view of a cover for a component
of a vehicle interior according to an exemplary embodiment.
[0080] FIG. 7D is a schematic view of first and second extrusion
dies for forming a cover for a component of a vehicle interior
according to an exemplary embodiment.
[0081] FIG. 7E is a schematic partial section view of a cover
precursor for a component of a vehicle interior according to an
exemplary embodiment.
[0082] FIG. 7F is a schematic partial section view of a cover for a
component of a vehicle interior engaged with a base of the
component according to an exemplary embodiment.
[0083] FIG. 8A is a schematic perspective view of a cover for a
component of a vehicle interior according to an exemplary
embodiment.
[0084] FIG. 8B is a schematic perspective exploded view of a cover
for a component of a vehicle interior according to an exemplary
embodiment.
[0085] FIG. 8C is a schematic side view of a cover for a component
of a vehicle interior according to an exemplary embodiment.
[0086] FIG. 8D is a schematic view of first and second extrusion
dies for forming a cover for a component of a vehicle interior
according to an exemplary embodiment.
[0087] FIG. 8E is a schematic perspective partial view of a cover
for a component of a vehicle interior according to an exemplary
embodiment.
[0088] FIG. 8F is a schematic partial section view of a cover for a
component of a vehicle interior engaged with a base of the
component according to an exemplary embodiment.
[0089] FIG. 9A is a schematic perspective view of a cover for a
component of a vehicle interior according to an exemplary
embodiment.
[0090] FIG. 9B is a schematic perspective exploded view of a cover
for a component of a vehicle interior according to an exemplary
embodiment.
[0091] FIG. 9C is a schematic side view of a cover for a component
of a vehicle interior according to an exemplary embodiment.
[0092] FIG. 9D is a schematic view of first and second extrusion
dies for forming a cover for a component of a vehicle interior
according to an exemplary embodiment.
[0093] FIG. 9E is a schematic partial side view of a cover
precursor for a component of a vehicle interior according to an
exemplary embodiment.
[0094] FIG. 9F is a schematic partial side view of a pin of a cover
for a component of a vehicle interior according to an exemplary
embodiment.
[0095] FIG. 9G is a schematic partial section view of a cover
precursor for a component of a vehicle interior coupled to a mold
for a pin of the cover for the component according to an exemplary
embodiment.
[0096] FIG. 9H is a schematic partial section view of a cover for a
component of a vehicle interior engaged with a base of the
component according to an exemplary embodiment.
[0097] FIG. 10A is a schematic perspective view of a cover for a
component of a vehicle interior according to an exemplary
embodiment.
[0098] FIG. 10B is a schematic perspective view of a cover for a
component of a vehicle interior according to an exemplary
embodiment.
[0099] FIG. 10C is a schematic front view of a cover for a
component of a vehicle interior according to an exemplary
embodiment.
[0100] FIG. 10D is a schematic view of first and second extrusion
dies for forming a cover for a component of a vehicle interior
according to an exemplary embodiment.
[0101] FIG. 10E is a schematic partial side view of a cover
precursor for a component of a vehicle interior according to an
exemplary embodiment.
[0102] FIG. 10F is a schematic partial section view of a cover for
a component of a vehicle interior engaged with a base of the
component according to an exemplary embodiment.
[0103] FIG. 11A is a schematic perspective view of a cover for a
component of a vehicle interior according to an exemplary
embodiment.
[0104] FIG. 11B is a schematic perspective view of a cover for a
component of a vehicle interior according to an exemplary
embodiment.
[0105] FIG. 11C is a schematic front view of a cover for a
component of a vehicle interior according to an exemplary
embodiment.
[0106] FIG. 11D is a schematic view of first and second extrusion
dies for forming a cover for a component of a vehicle interior
according to an exemplary embodiment.
[0107] FIG. 11E is a schematic partial top view of a cover
precursor for a component of a vehicle interior according to an
exemplary embodiment.
[0108] FIG. 11F is a schematic partial section view of a cover for
a component of a vehicle interior engaged with a base of the
component according to an exemplary embodiment.
[0109] FIG. 12A is a schematic perspective view of a cover for a
component of a vehicle interior according to an exemplary
embodiment.
[0110] FIG. 12B is a schematic perspective exploded view of a cover
for a component of a vehicle interior according to an exemplary
embodiment.
[0111] FIG. 12C is a schematic side view of a cover for a component
of a vehicle interior according to an exemplary embodiment.
[0112] FIG. 12D is a schematic view of an extrusion die for forming
a cover for a component of a vehicle interior according to an
exemplary embodiment.
[0113] FIG. 12E is a schematic partial perspective view of a cover
precursor for a component of a vehicle interior according to an
exemplary embodiment.
[0114] FIG. 12F is a schematic partial section view of a cover for
a component of a vehicle interior engaged with a base of the
component according to an exemplary embodiment.
[0115] FIG. 13A is a schematic perspective view of a cover for a
component of a vehicle interior according to an exemplary
embodiment.
[0116] FIG. 13B is a schematic perspective exploded view of a cover
for a component of a vehicle interior according to an exemplary
embodiment.
[0117] FIG. 13C is a schematic side view of a cover for a component
of a vehicle interior according to an exemplary embodiment.
[0118] FIG. 13D is a schematic view of an extrusion die for forming
a cover for a component of a vehicle interior according to an
exemplary embodiment.
[0119] FIG. 13E is a schematic partial perspective view of a cover
for a component of a vehicle interior according to an exemplary
embodiment.
[0120] FIG. 13F is a schematic partial section view of a cover for
a component of a vehicle interior engaged with a base of the
component according to an exemplary embodiment.
[0121] FIG. 14A is a schematic perspective view of a cover for a
component of a vehicle interior according to an exemplary
embodiment.
[0122] FIG. 14B is a schematic perspective exploded view of a cover
for a component of a vehicle interior according to an exemplary
embodiment.
[0123] FIG. 14C is a schematic side view of a cover for a component
of a vehicle interior according to an exemplary embodiment.
[0124] FIG. 14D is a schematic view of an extrusion die for forming
a cover for a component of a vehicle interior according to an
exemplary embodiment.
[0125] FIG. 14E is a schematic perspective view of a cover for a
component of a vehicle interior according to an exemplary
embodiment.
[0126] FIG. 14F is a schematic perspective partial view of a cover
for a component of a vehicle interior according to an exemplary
embodiment.
[0127] FIG. 14G is a schematic partial section view of a cover for
a component of a vehicle interior engaged with a base of the
component according to an exemplary embodiment.
[0128] FIG. 15A is a schematic perspective view of a cover for a
component of a vehicle interior according to an exemplary
embodiment.
[0129] FIG. 15B is a schematic perspective exploded view of a cover
for a component of a vehicle interior according to an exemplary
embodiment.
[0130] FIG. 15C is a schematic side view of a cover for a component
of a vehicle interior according to an exemplary embodiment.
[0131] FIG. 15D is a schematic view of an extrusion die for forming
a cover for a component of a vehicle interior according to an
exemplary embodiment.
[0132] FIG. 15E is a schematic partial side view of a cover for a
component of a vehicle interior according to an exemplary
embodiment.
[0133] FIG. 15F is a schematic perspective partial view of a cover
for a component of a vehicle interior according to an exemplary
embodiment.
[0134] FIG. 15G is a schematic partial section view of a cover for
a component of a vehicle interior engaged with a base of the
component according to an exemplary embodiment.
[0135] FIG. 16A is a schematic perspective view of a cover for a
component of a vehicle interior according to an exemplary
embodiment.
[0136] FIG. 16B is a schematic perspective exploded view of a cover
for a component of a vehicle interior according to an exemplary
embodiment.
[0137] FIG. 16C is a schematic side view of a cover for a component
of a vehicle interior according to an exemplary embodiment.
[0138] FIG. 16D is a schematic view of an extrusion die for forming
a cover for a component of a vehicle interior according to an
exemplary embodiment.
[0139] FIG. 16E is a schematic partial side view of a cover for a
component of a vehicle interior according to an exemplary
embodiment.
[0140] FIG. 16F is a schematic perspective partial view of a cover
for a component of a vehicle interior according to an exemplary
embodiment.
[0141] FIG. 16G is a schematic partial section view of a cover for
a component of a vehicle interior engaged with a base of the
component according to an exemplary embodiment.
[0142] FIG. 17A is a schematic perspective view of a cover for a
component of a vehicle interior according to an exemplary
embodiment.
[0143] FIG. 17B is a schematic perspective exploded view of a cover
for a component of a vehicle interior according to an exemplary
embodiment.
[0144] FIG. 17C is a schematic side view of a cover for a component
of a vehicle interior according to an exemplary embodiment.
[0145] FIG. 17D is a schematic view of an extrusion die for forming
a cover for a component of a vehicle interior according to an
exemplary embodiment.
[0146] FIG. 17E is a schematic partial side view of a cover
precursor for a component of a vehicle interior according to an
exemplary embodiment.
[0147] FIG. 17F is a schematic partial side view of a pin of a
cover for a component of a vehicle interior according to an
exemplary embodiment.
[0148] FIG. 17G is a schematic partial perspective view of a cover
precursor for a component of a vehicle interior coupled to a mold
for a pin of the cover for the component according to an exemplary
embodiment.
[0149] FIG. 17H is a schematic partial section view of a cover for
a component of a vehicle interior engaged with a base of the
component according to an exemplary embodiment.
[0150] FIG. 18A is a schematic perspective view of a cover for a
component of a vehicle interior according to an exemplary
embodiment.
[0151] FIG. 18B is a schematic front view of a cover for a
component of a vehicle interior according to an exemplary
embodiment.
[0152] FIG. 18C is a schematic view of an extrusion die for forming
a cover for a component of a vehicle interior according to an
exemplary embodiment.
[0153] FIG. 18D is a schematic partial side view of a cover
precursor for a component of a vehicle interior according to an
exemplary embodiment.
[0154] FIG. 18E is a schematic partial perspective view of a cover
for a component of a vehicle interior according to an exemplary
embodiment.
[0155] FIG. 18F is a schematic partial section view of a cover for
a component of a vehicle interior engaged with a base of the
component according to an exemplary embodiment.
DESCRIPTION
[0156] Referring to FIGS. 1A and 1B, a vehicle V is shown
schematically according to an exemplary embodiment providing a
vehicle interior component shown as a console in the form of a
floor console FC. As shown schematically according to an exemplary
embodiment in FIGS. 1B and 1C, console FC comprises a base or base
structure B providing a compartment with an opening; console FC
comprises a movable door shown as a tambour door TD for the
compartment (see FIG. 1D).
[0157] As shown schematically in FIGS. 1B-1C and 2A-2C, door TD can
be moved relative to the opening of compartment (e.g.
moved/translated in a guide or track system in base structure B)
from a closed position blocking/limiting access to the compartment
(see FIGS. 1C and 2A) to an open position permitting access to the
compartment (see FIGS. 1B and 2B-2C). As indicated schematically in
FIGS. 2A-2C, door assembly TD may comprise a generally flexible
structure (e.g. semi-rigid, bendable, segmented, etc.) configured
to bend freely according to the form or shape of the guide or
track; as shown schematically according to an exemplary embodiment
in FIGS. 2A-2C, the guide or track system for door or door assembly
TD may be provided in a curved form and door TD may be configured
to flex/bend as guided by an external force such as the hand H of
an occupant of the vehicle directing movement of door TD in and
along the guide of the track system (e.g. a generally continuous
set of tracks to engage an interface of door TD).
[0158] As shown schematically in FIGS. 1D and 2D, door TD may
comprise a door assembly comprising a cover or cover layer (e.g.
providing an exterior appearance and/or surface) and a carrier or
substrate section (e.g. providing a structure and/or interface with
the base of the console); as shown schematically, the carrier or
substrate section of door assembly TD may provide a set of
projections (along each side of the door/carrier) configured to
engage a set of guides shown tracks (along each side of the opening
of the compartment) of the base of the console 1000 to allow door
TD to be moved between the open position and the closed position.
See also FIGS. 2A-2C and 2E-2F. As shown schematically according to
an exemplary embodiment in FIG. 2D, the carrier or substrate
section of door assembly TD may comprise a set of transverse
segments shown as ribs (e.g. to provide door TD with a generally
flexible structure as indicated in FIGS. 2A-2C); the set of
projections for door TD may be provided by a set of members shown
as posts that are coupled/attached to the segments of the carrier
or substrate section (and extend laterally beyond the cover/cover
layer) to engage the guide or track of the base structure of the
console.
[0159] As shown schematically in FIGS. 2D and 2E, the interface of
door assembly TD at the opening of the compartment of the base
structure 1010 of the console may have a generally symmetrical form
(e.g. with each set of the projections on each side of the door
configured to engage a guide or track on each side of the opening
of the compartment). See also for example FIGS. 9B, 10B, 13B,
15A-15B, 16A-16B, 17A-17B, and 18A-18B.
[0160] Referring to FIGS. 3A-3F, according to an exemplary
embodiment, a door assembly 3100 may comprise a cover 3110 and a
carrier structure 3120 providing the set of projections (e.g.
formed by machining with a cutting tool CT) for engagement of the
guide/track of a base 3010/3012 of the console; cover 3110 and
carrier structure 3120 may be formed into door assembly 3100 in a
tool shown as mold D3110/D3120. As indicated schematically, cover
3110 may comprise a compliant material/layer such as a foam (see
FIG. 3F); door assembly 3100 may be constructed by folding edges
(e.g. leading and trailing) of cover 3110 on carrier structure
3120. As shown schematically, the projections of carrier structure
3120 of door assembly 3100 may comprise a feature such as set of
posts that is exposed when a portion of the cover section is
machined (e.g. by a tool such as a cutting tool CT). See FIGS. 3E,
4E, 5E, 7E, 9E, 10E, 11E, 12E and 18D.
[0161] According to an exemplary embodiment, the door may be
prepared by a process comprising the step of forming (e.g. molding,
extruding, etc.) a material into the substrate/carrier to form an
extruded structure for (or with) the cover/cover layer. See for
example FIGS. 3D, 14D, 15D and 18C. The process may comprise the
step of removing a portion of the extruded substrate to form the
set of projections. See for example FIGS. 3E, 4E, 5E, 7E, 9E, 10E,
11E, 12E and 18D.
[0162] As shown schematically in the FIGURES according to an
exemplary embodiment, the door or door assembly may be provided in
any of a wide variety of forms/structures (such as multi-layered,
multi-sectioned, etc.) by any of a wide variety of forming
techniques (including but not limited to extrusion/co-extrusion,
injection molding, machining/cutting, component assembly, adhesive
bonding, forming, etc.) and from a wide variety of materials
(including plastics, extruded plastics/resins, molded resins,
injection molded resins, composite materials, fiber-based
materials, etc.).
[0163] As shown schematically according to an exemplary embodiment
for the door assembly, the carrier may comprise a base or base
structure (see FIGS. 4A-4G); the base or base structure may
comprise the cover and provide a structure such as a set of
grooves/channels or ribs for attachment of a carrier providing a
set of projections (e.g. formed and/or machined) (see FIGS. 5A-5F);
the base or base structure may comprise a carrier configured with
apertures for attachment of a set of projections shown as posts or
pegs (e.g. by interference fit, insertion, adhesive, etc.) (see
FIGS. 6A-6F); the base or base structure may comprise a carrier
comprising a multi-layer structure formed to provide a set of ribs
attached to the cover layer and machined to provide a set of
projections shown as a rim (e.g. by a cutting tool CT) (see FIGS.
7A-7F); the cover and the carrier may be integrally formed and
attached (e.g. formed, injection molded, folded, etc.) to provide a
multi-layer construction (see FIGS. 14A-14G); the cover may be
integrally formed with the carrier configured with apertures for
attachment of a set of projections shown as posts or pegs (e.g. by
interference fit, insertion, adhesive, forming, molding/co-molding,
etc.) (see FIGS. 15A-15G, 16A-16G and 17A-17H); the door assembly
may comprise an integrated cover/carrier comprising the set of
projections (e.g. formed, extruded, integrally formed, formed and
machined, etc.) (see FIGS. 18A-18F).
[0164] As shown schematically according to an exemplary embodiment
for the door assembly, the carrier may comprise a base or base
structure providing a carrier configured with a set of projections
shown as posts or pegs providing a feature such as a head
configured to fit in the guide or track of the base of the console
(e.g. knob, cap, machined end, etc.) (see FIGS. 8A-8F); the carrier
may comprise a base or base structure configured with a set of
projections shown as posts or pegs providing a feature such as a
head configured to fit in the guide or track of the base of the
console (e.g. knob, cap, machined end, etc.) and attached to a
feature such as a projection on the carrier (see FIGS. 9A-9G and
16A-16G); the carrier may comprise a set of flanges formed with a
set of projections and attached to the sides of the cover (e.g.
formed, extruded, co-extruded, formed and machined, extruded and
machined, co-extruded and machined, etc.) (see FIGS. 10A-10F); the
base or base structure may comprise a carrier structure formed to
provide a set of projections comprising a set of guides configured
to engage the guide or track of the base of the console (e.g. a set
of rims, tracks, channels, flanges, etc.) (see FIGS. 11A-11F); the
carrier may comprise a set of separate segments such members (e.g.
rods, posts, etc.) or attached/inserted into apertures (e.g. as
pins, posts, pegs) providing the set of projections (e.g. formed,
machined, etc.) (see FIGS. 12A-12F and 13A-13F).
[0165] As shown schematically according to an exemplary embodiment
in the FIGURES, the vehicle interior component may comprise a base
providing a compartment with an opening and a door configured for
movement relative to the base to an open position to facilitate
access through the opening into the compartment of the base. See
FIGS. 2A-2C. According to an exemplary embodiment shown
schematically in FIGS. 2F, 3F and 4F, an interface may be provided
between the base and the door configured to facilitate movement of
the door relative to the base. See also FIGS. 5F, 6F, 7F, 8F, 9H,
10F, 11F, 12F, 13F, 14G, 15G, 16G, 17H and 18F. As indicated
schematically, the interface may comprise a set of projections on
the door configured to engage a set of guides on the base. See
generally FIGS. 2F, 3F, 4F, 5F, 6F, 7F, 8F, 9H, 10F, 11F, 12F, 13F,
14G, 15G, 16G, 17H and 18F (example arrangements of components the
interface).
[0166] According to an exemplary embodiment shown schematically in
the FIGURES, the set of projections may be formed or extruded (e.g.
molded, extrusion-formed, etc.). According to an exemplary
embodiment, the set of projections may be formed by extruding a
polymer material in a direction substantially perpendicular to a
path of movement of the door relative to the base. See e.g. FIGS.
10A-10D. The set of projections may be formed by extruding a
polymer material in a direction substantially parallel to a path of
movement of the door relative to the base. See e.g. FIGS.
18A-18D.
[0167] According to an exemplary embodiment, the door (e.g.
carrier, cover, structure, etc.) may be formed by molding and/or
extrusion; the set of projections on the door (e.g. carrier, base
structure, etc.) may be formed by machining (e.g. a milling/cutting
operation. See generally FIGS. 3E, 4E, 5E, 7E, 9E, 10E, 11E, 12E
and 18D. According to an exemplary embodiment, the carrier of the
door/door assembly may comprise a set of openings shown as
apertures; the set of projections (e.g. pins, posts, pegs, members,
knobs, caps, extensions, rims, flanges, channels, etc.) may be
coupled to the door at the set of openings. See for example FIGS.
6E-6F, 8E-8F, 9F-9H, 13E-13F, 14F-14G, 15E-15G, 16E-16G and
17F-17H. The door may comprise a set of channels (e.g. grooves,
slots, etc.); the set of projections may extend into and/or through
the set of channels. See generally FIGS. 2A-2D. The door may
comprise at least one of a set of apertures or a set of grooves;
and the set of projections may be inserted into the at least one of
the set of apertures or the set of grooves. See generally FIGS.
6A-6F, 8A-8F, 9A-9H, 13A-13F, 14A-14G, 15A-15G, 16A-16G and
17A-17H.
[0168] According to an exemplary embodiment, the door may comprise
a substrate and a cover layer; the substrate may comprise an
extrusion; the cover layer may comprise an extrusion. According to
an exemplary embodiment, the substrate and the cover layer may be
formed by co-extrusion. See generally FIGS. 10A-10F. According to
an exemplary embodiment, the cover layer may be bonded to the
substrate as the substrate is extruded. See for example FIGS. 3D,
4D, 5D, 6D, 7D, 8D and 9D. According to an exemplary embodiment,
the substrate and cover layer may be integrally formed. See for
example FIGS. 14D-14E and 18C.
[0169] According to an exemplary embodiment, the set of projections
may comprise at least one of (a) a set of projections formed on the
door; (b) a set of pins formed on the door; (c) a set of posts
formed on the door; (d) a set of members formed on the door; (e) a
set of features formed on the door; (f) a set of pegs formed on the
door; (g) a rim formed on the door; (h) a support formed on the
door; (i) a flange formed on the door. According to an exemplary
embodiment, the set of projections may comprise at least one of (a)
a set of projections integrally formed on the door; (b) a set of
pins integrally formed on the door; (c) a set of posts integrally
formed on the door; (d) a set of members integrally formed on the
door; (e) a set of features integrally formed on the door; (f) a
set of pegs integrally formed on the door; (g) a rim integrally
formed on the door; (h) a support integrally formed on the door;
(i) a flange integrally formed on the door.
[0170] The door may comprise a door assembly; the door assembly may
comprise at least one of (a) a cover and a substrate; (b) a cover
and a base; (c) a cover structure and a carrier structure; (d) a
cover and a carrier structure; (e) a base structure comprising a
cover and a substrate comprising the set of projections; (f) a
cover and a base structure formed by co-extrusion; (g) a cover and
a carrier structure formed by co-extrusion; (h) a cover and a
carrier formed by co-extrusion; (i) a cover coupled to a carrier
formed by extrusion.
[0171] According to an exemplary embodiment, a method of making a
component for a vehicle interior comprising a base and a door
configured for movement relative to the base to an open position to
facilitate access through the opening into a compartment of the
base and a set of projections on the door configured to engage a
set of guides on the base may comprise the step of forming the door
by extrusion of polymer material through a tool. See for example
FIGS. 3C-3D, 4C-4D, 5C-5D, 6C-6D, 7C-7D, 8C-8D, 9C-9D, 10C-10D,
11C-11D, 12C-12D, 13C-13D, 14C-14D, 15C-15D, 16C-16D and 17C-17D.
The door may comprise a cover and a carrier configured to provide
the set of projections; the method may further comprise the step of
forming the set of projections on the carrier; the method may
further comprise the step of attaching the set of projections to
the carrier. See for example FIGS. 2D-2F, 3E, 4E, 5E, 6E, 8E, 9H,
10E, 11E-11F, 12E, 13F, 14F, 15F, 16F, 17F and 18D-18E. According
to an exemplary embodiment, the step of forming the door may
comprise extruding a polymer material to form the carrier; the step
of forming the door further may comprise bonding the cover to the
carrier. See for example FIGS. 14A-14E. According to an exemplary
embodiment, the step of forming the door may comprise extruding a
polymer material to form the cover. See for example FIGS. 10A-10D.
The step of forming the door may comprise extruding a first polymer
material to form a carrier and extruding a second polymer material
to form a cover; the step of forming the door may comprise
extruding the first polymer material in a first direction to form
the carrier and extruding the second polymer material in a second
direction to form the cover. See for example FIGS. 10A-10D. The
door may comprise a cover and a carrier configured to provide the
set of projections. See for example FIGS. 3B, 4B, 5B, 6B, 7B, 8B,
9B and 10B.
[0172] According to an exemplary embodiment, the vehicle interior
component may comprise a base providing a compartment with an
opening and a door configured for movement relative to the base to
an open position to facilitate access through the opening into the
compartment of the base and an interface between the base and the
door configured to facilitate movement of the door relative to the
base; the interface may comprise a set of projections on the door
configured to engage a set of guides on the base; the door may
comprise a carrier configured to provide the set of projections and
a cover. See for example FIGS. 3B, 4B, 5B, 6B, 7B, 8B, 9B, 10B,
11B, 12B, 13B and 14B.
[0173] According to an exemplary embodiment, the door may be formed
by extrusion. The set of projections may be formed on the carrier.
According to an exemplary embodiment, the carrier may be formed by
extrusion of a polymer material. According to an exemplary
embodiment, the cover may be formed by extrusion of a polymer
material. According to an exemplary embodiment, the door may be
formed by attachment of the cover to the carrier; the door may be
formed by co-extrusion of the cover and the carrier; the cover and
the carrier may be integrally formed; the cover may be bonded to
the carrier. See for example FIGS. 10A-10D, 14A-14G and 15A-15D,
16A-16D, 17A-17D and 18A-18D.
[0174] According to an exemplary embodiment, the set of projections
may be formed by extrusion of the carrier; the set of projections
may be formed by machining of the carrier; the set of projections
may be attached to the carrier. See for example FIGS. 2D-2F, 3E,
4E, 5E, 6E, 8E, 9H, 10E, 11E-11F, 12E, 13F, 14F, 15F, 16F, 17F and
18D-18E. According to an exemplary embodiment, the set of
projections may comprise at least one of (a) a set of projections
formed on the carrier; (b) a set of pins formed on the carrier; (c)
a set of posts formed on the carrier; (d) a set of members formed
on the carrier; (e) a set of features formed on the carrier; (f) a
set of pegs formed on the carrier; (g) a rim formed on the carrier;
(h) a support formed on the carrier; (i) a set of supports formed
on the carrier; (j) a flange formed on the carrier; (k) a set of
flanges formed on the carrier; (l) a set of projections attached to
the carrier; (m) a set of projections attached in a set of
apertures on the carrier; (n) a set of projections integrally
formed on the carrier; (o) a set of projections formed by machining
of the carrier; (p) a set of projections comprising a set of
features formed by machining of the carrier. See for example FIGS.
2D-2F, 3E, 4E, 5E, 6E, 8E, 9H, 10E, 11E-11F, 12E, 13F, 14F, 15F,
16F, 17F and 18D-18E.
[0175] The door may comprise a door assembly. See for example FIGS.
3A-3B, 4A-4B, 5A-5B, 6A-6B, 7A-7B, 8A-8B, 9A-9B, 10A-10B, 11A-11B,
12A-12B, 13A-13B and 14A-14B. The door assembly may comprise at
least one of (a) a cover and a substrate; (b) a cover and a base;
(c) a cover structure and a carrier structure; (d) a cover and a
carrier structure; (e) a base structure comprising a cover and a
substrate comprising the set of projections; (f) a cover and a base
structure formed by co-extrusion; (g) a cover and a carrier
structure formed by co-extrusion; (h) a cover and a carrier formed
by co-extrusion; (i) a cover coupled to a carrier formed by
extrusion.
Exemplary Embodiments
[0176] According to an exemplary embodiment as shown schematically
in FIGS. 1A to 1D, a vehicle V is shown including an interior with
a component or floor console FC. Floor console FC may comprise a
base B and a cover provided by and/or as a door shown as a tambour
door TD. See also generally FIGS. 2A-2D, 3A-3C, 4A-4C, 5A-5C,
6A-6C, 7A-7C, 8A-8C, 9A-9C, 10A-10C, 11A-11C, 12A-12C, 13A-13C,
14A-14C, 15A-15C, 16A-16C, 17A-17C and 18A-18B (e.g. various
arrangements of door/door assembly as and/or providing a cover
according to exemplary embodiment).
[0177] According to an exemplary embodiment as shown schematically
in FIGS. 2A to 2C, a component 1000 (e.g. vehicle trim component,
console, center console, floor console, storage compartment, arm
rest, etc.) is shown for a vehicle interior. As shown
schematically, component 1000 may comprise a base 1010 and a cover
provided by and/or as a door shown as a tambour door TD. The cover
or door shown as tambour door TD may be configured to conform to
the curved structure of the base 1010 as the tambour door TD moves
between a closed position and an open position to facilitate access
to the storage compartment. According to an exemplary embodiment, a
hand H may exert an external force to move the tambour door TD from
the closed position to the open position. As shown schematically in
FIGS. 2F and 2E, base 1010 may comprise a first wall 1012 and a
second wall 2014 opposite first wall 1012. The cover or door shown
as tambour door TD may be configured to engage with base 1010 of
component 1000.
[0178] According to an exemplary embodiment as shown schematically
in FIGS. 5A to 5C, a cover 2100 (e.g. provided by or as a door,
tambour door, door assembly, shade, blind, roller blind, etc.) is
shown. As shown schematically in FIGS. 5A to 5C, cover 2100 may
comprise a visible surface 2100v, a mounting aperture 2109, a top
layer or substrate 2110, and a bottom layer or pins 2120 (e.g.
extensions, projections, pegs, posts, features, etc.). As shown
schematically in FIG. 5C, substrate 2110 may comprise a series of
substantially parallel ribs 2111. According to an exemplary
embodiment, mounting aperture 2109 may be configured to receive a
handle or similar structure to help facilitate movement of cover
2100 from a closed position to an open position when cover 2100 is
coupled to base 1010. According to an exemplary embodiment,
substantially parallel ribs 2111 may be configured to move relative
to one another to facilitate bending of cover 2100. According to an
exemplary embodiment, pins 2120 may be configured to be bonded to
substrate 2110 at each of the substantially parallel ribs 2120.
According to an exemplary embodiment, substrate 2110 may be
comprised of a first material and pins 2120 may be comprised of a
second material different than the first material. According to an
exemplary embodiment, pins 2120 may be formed in a single
monolithic structure with substrate 2110.
[0179] According to an exemplary embodiment as shown schematically
in FIGS. 5D and 5E, cover 2100 may be formed by a combination of an
extrusion process and a cutting process (e.g. employing tooling,
fixtures, etc.). A first polymer material may be extruded through a
first extrusion die D11 in a direction substantially perpendicular
to a direction of travel of the cover 2100 when cover 2100 is
coupled to base 1010 to from a top layer of a precursor (e.g.
section or segment of cover/door) 201. A second polymer material
may be extruded through a second extrusion die D12 in a direction
substantially perpendicular to a direction of travel of the cover
2100 when cover 2100 is coupled to base 1010 to form a bottom layer
of a cover precursor 201. As shown schematically in FIG. 5D, first
and second extrusion dies D11 and D12 may be configured to allow
the first and second polymer materials to pass through the cut out
sections (see portions of FIG. 5D without cross hatching). Once the
first and second polymer materials pass through first and second
extrusion dies D11 and D12 the first and second polymer materials
may begin to dry and harden on the opposite side of first and
second extrusion dies D11 and D12 into cover precursor 201 with a
shape that partially matches a side profile of substrate 2110.
According to an exemplary embodiment, the bottom layer may be
bonded to the top layer during the extrusion process. According to
an exemplary embodiment, extruding the first polymer material
through first extrusion die D11 may occur simultaneously with
extruding the second polymer material through second extrusion die
D12. According to an exemplary embodiment, extruding the second
polymer through second extrusion die D12 may be started before
extruding the first polymer material through first extrusion die
D11 and stopped after extruding the first polymer material through
first extrusion die D11 has stopped so as to directly form
substrate 2110 into a core and an extension 2100e (see FIGS. 5E and
5F) without employing the cutting process.
[0180] According to an exemplary embodiment as shown schematically
in FIG. 5E, precursor (e.g. section or segment of cover/door) 201
may be cut with cutting tool CT to cut away portions of cover
precursor 201 to form substrate 2110 into a core and an extension
2100e. According to an exemplary embodiment, cutting tool CT may
cut in a U-shaped pattern to form extension 2100e. According to an
exemplary embodiment, the core may comprise a first thickness and
extension 2100e may comprise a second thickness less than the first
thickness. According to an exemplary embodiment, extension 2100e
may comprise a portion of pins 2120 (e.g. extensions, projections,
pegs, posts, features, etc.).
[0181] According to an exemplary embodiment as shown schematically
in FIG. 5F, door/cover 2100 may be configured to engage with base
1010 to facilitate movement of cover 2100 relative to base 1010
between a closed position and an open position. Extension 2100e may
be configured to engage base 1010 and the core may be configured to
extend between first wall 1012 and second wall 2014 (see FIG. 2E).
According to an exemplary embodiment, pins 2120 may be configured
to engage with base 1010. According to an exemplary embodiment,
visible surface 2100v, which may be substantially flat and smooth
as a result of the extrusion process, may comprise a soft to touch
feel from a finger F in comparison to pins 2120 as a result of
visible surface 2100v being formed by the first polymer material
and pins 2120 being formed by the second polymer material.
[0182] According to an exemplary embodiment as shown schematically
in FIGS. 6A to 6C, a cover 2200 (e.g. provided by or as a door,
tambour door, door assembly, shade, blind, roller blind, etc.) is
shown. As shown schematically in FIGS. 6A to 6C, cover 2200 may
comprise a visible surface 2200v, a mounting aperture 2209, a top
layer 2210, a bottom layer 2215 (e.g. substrate, layer, platform,
carrier, structure, etc.), and pins 2220 (e.g. extensions,
projections, pegs, posts, features, etc.). As shown schematically
in FIGS. 6B and 6C, visible surface 2200v and mounting aperture
2209 may be integrated with top layer 2210. According to an
exemplary embodiment, mounting aperture 2209 may be configured to
receive a handle or similar structure to help facilitate movement
of cover 2200 from the closed position to the open position when
cover 2200 is coupled to base 1010. As shown schematically in FIG.
6C, bottom layer 2215 may comprise a series of substantially
parallel ribs 2211 and openings 2214. According to an exemplary
embodiment, substantially parallel ribs 2211 may be configured to
move relative to one another to facilitate bending of cover 2200.
According to an exemplary embodiment, pins 2220 may be configured
to be coupled to bottom layer 2215 at openings 2214 (see FIGS. 6B
and 6E). According to an exemplary embodiment, pins 2220 may
comprise a first set of pins 2222 and a second set of pins 2224.
According to an exemplary embodiment, each pin of first and second
sets of pins 2222 and 2224 may comprise a first portion configured
to couple each of the pins to the openings 2214 and a second
portion configured to engage base 1010 (see FIGS. 6B and 6E).
According to an exemplary embodiment, pins 2220 may be configured
to pass entirely though substrate 2210. According to an exemplary
embodiment, first layer 2210 may be comprised of a first material
and second layer 2215 may be comprised of a second material
different than the first material.
[0183] According to an exemplary embodiment as shown schematically
in FIG. 6D, cover 2200 may be formed by an extrusion process. A
first polymer material may be extruded through a first extrusion
die D21 in a direction substantially perpendicular to a direction
of travel of the cover 2200 when cover 2200 is coupled to base 1010
to top layer 2210. A second polymer material may be extruded
through a second extrusion die D22 in a direction substantially
perpendicular to a direction of travel of the cover 2200 when cover
2200 is coupled to base 1010 to form bottom layer 2215 (e.g.
substrate, layer, platform, carrier, structure, etc.). As shown
schematically in FIG. 6D, first and second extrusion dies D21 and
D22 may be configured to allow the first and second polymer
materials to pass through the cut out sections (see portions of
FIG. 6D without cross hatching). Once the first and second polymer
materials pass through first and second extrusion dies D21 and D22
the first and second polymer materials may begin to dry and harden
on the opposite side of first and second extrusion dies D21 and D22
into top and bottom layers 2210 and 2215. According to an exemplary
embodiment, extruding the first polymer material through first
extrusion die D21 may occur simultaneously with extruding the
second polymer material through second extrusion die D22. According
to an exemplary embodiment, bottom layer 2215 may be bonded to top
layer 2210 during the extrusion process.
[0184] According to an exemplary embodiment as shown schematically
in FIG. 6E, pins 2220 may be inserted into openings 2214 of bonded
top and bottom layers 2210 and 2215 to form a core and an extension
2200e. According to an exemplary embodiment, the core may comprise
a first thickness and extension 2200e may comprise a second
thickness less than the first thickness. According to an exemplary
embodiment, extension 2200e may comprise a portion of pins
2220.
[0185] According to an exemplary embodiment as shown schematically
in FIG. 6F, door/cover 2200 may be configured to engage with base
1010 to facilitate movement of cover 2200 relative to base 1010
between a closed position and an open position. Extension 2200e may
be configured to engage base 1010 and the core may be configured to
extend between first wall 1012 and second wall 2014 (see FIG. 2E).
According to an exemplary embodiment, pins 2220 may be configured
to engage with base 1010. According to an exemplary embodiment,
visible surface 2200v, which may be substantially flat and smooth
as a result of the extrusion process, may comprise a soft to touch
feel from a finger F in comparison to bottom layer 2215 as a result
of visible surface 2200v being formed by the first polymer material
and bottom layer 2215 being formed by the second polymer
material.
[0186] According to an exemplary embodiment as shown schematically
in FIGS. 7A to 7C, a cover 2300 (e.g. provided by or as a door,
tambour door, door assembly, shade, blind, roller blind, etc.) is
shown. As shown schematically in FIGS. 7A to 7C, cover 2300 may
comprise a visible surface 2300v, a mounting aperture 2309, a top
layer 2310, and a bottom layer 2320. As shown schematically in
FIGS. 7B and 7C, visible surface 2300v and mounting aperture 2309
may be integrated with top layer 2310. According to an exemplary
embodiment, mounting aperture 2309 may be configured to receive a
handle or similar structure to help facilitate movement of cover
2300 from the closed position to the open position when cover 2300
is coupled to base 1010. As shown schematically in FIG. 7C, bottom
layer 2320 may comprise a series of substantially parallel ribs
2111. According to an exemplary embodiment, substantially parallel
ribs 2311 may be configured to move relative to one another to
facilitate bending of cover 2300. According to an exemplary
embodiment, bottom layer 2320 may be configured to be bonded to top
layer 2310. According to an exemplary embodiment, top layer 2310
may be comprised of a first material and bottom layer 2320 may be
comprised of a second material different than the first material.
According to an exemplary embodiment, bottom layer 2320 may be
formed in a single monolithic structure with top layer 2310.
[0187] According to an exemplary embodiment as shown schematically
in FIGS. 7D and 7E, cover 2300 may be formed by a combination of an
extrusion process and a cutting process (e.g. employing tooling,
fixtures, etc.). A first polymer material may be extruded through a
first extrusion die D31 in a direction substantially perpendicular
to a direction of travel of the cover 2300 when cover 2300 is
coupled to base 1010 to from a top layer of a precursor (e.g.
section or segment of cover/door) 301. A second polymer material
may be extruded through a second extrusion die D32 in a direction
substantially perpendicular to a direction of travel of the cover
2300 when cover 2300 is coupled to base 1010 to form a bottom layer
of a cover precursor 301. As shown schematically in FIG. 7D, first
and second extrusion dies D31 and D32 may be configured to allow
the first and second polymer materials to pass through the cut out
sections (see portions of FIG. 7D without cross hatching). Once the
first and second polymer materials pass through first and second
extrusion dies D31 and D32 the first and second polymer materials
may begin to dry and harden on the opposite side of first and
second extrusion dies D31 and D32 into cover precursor 301 with a
shape that partially matches a side profile of cover 2300.
According to an exemplary embodiment, the bottom layer may be
bonded to the top layer during the extrusion process. According to
an exemplary embodiment, extruding the first polymer material
through first extrusion die D31 may occur simultaneously with
extruding the second polymer material through second extrusion die
D32. According to an exemplary embodiment, extruding the second
polymer through second extrusion die D32 may be started before
extruding the first polymer material through first extrusion die
D31 and stopped after extruding the first polymer material through
first extrusion die D31 has stopped so as to directly form top
layer 2310 into a core and an extension 2300e (see FIGS. 7E and 7F)
without employing the cutting process.
[0188] According to an exemplary embodiment as shown schematically
in FIG. 7E, cover precursor 301 may be cut with cutting tool CT to
cut away a portion 2310B of cover precursor 301 to form top layer
2310 into the core and extension 2300e. According to an exemplary
embodiment, cutting tool CT may cut in a level path perpendicular
to a front face of cover precursor 301 to form extension 2300e.
According to an exemplary embodiment, the core may comprise a first
thickness and extension 2300e may comprise a second thickness less
than the first thickness.
[0189] According to an exemplary embodiment as shown schematically
in FIG. 7F, door/cover 2300 may be configured to engage with base
1010 to facilitate movement of cover 2300 relative to base 1010
between a closed position and an open position. Extension 2300e may
be configured to engage base 1010 and the core may be configured to
extend between first wall 1012 and second wall 2014 (see FIG. 2E).
According to an exemplary embodiment, visible surface 2300v, which
may be substantially flat and smooth as a result of the extrusion
process, may comprise a soft to touch feel from a finger F in
comparison to bottom layer 2320 as a result of the visible surface
2300v being formed by the first polymer material and bottom layer
2320 being formed by the second polymer material.
[0190] According to an exemplary embodiment as shown schematically
in FIGS. 8A to 8C, a cover 2400 (e.g. provided by or as a door,
tambour door, door assembly, shade, blind, roller blind, etc.) is
shown. As shown schematically in FIGS. 8A to 8C, cover 2400 may
comprise a visible surface 2400v, a mounting aperture 2409, a top
layer 2410, a bottom layer 2415 (e.g. substrate, layer, platform,
carrier, structure, etc.), and pins 2420 (e.g. extensions,
projections, pegs, posts, features, etc.). As shown schematically
in FIGS. 8B and 8C, visible surface 2400v and mounting aperture
2409 may be integrated with top layer 2410. According to an
exemplary embodiment, mounting aperture 2409 may be configured to
receive a handle or similar structure to help facilitate movement
of cover 2400 from the closed position to the open position when
cover 2400 is coupled to base 1010. As shown schematically in FIG.
8C, bottom layer 2415 may comprise a series of substantially
parallel ribs 2411 and openings 2414. According to an exemplary
embodiment, substantially parallel ribs 2411 may be configured to
move relative to one another to facilitate bending of cover 2400.
According to an exemplary embodiment, top layer 2410 may be
comprised of a first material and bottom layer 2415 may be
comprised of a second material different than the first
material.
[0191] According to an exemplary embodiment, pins 2420 may be
configured to be coupled to bottom layer 2415 at openings 2414 (see
FIGS. 8B and 8E). According to an exemplary embodiment as shown
schematically in FIGS. 8C and 8E, substantially parallel ribs 2411
may be configured in a tear drop shape and openings 2414 may also
be configured in a tear drop shape to increase surface contact with
pins 2420. According to an exemplary embodiment, pins 2420 may
comprise a first set of pins 2422 and a second set of pins 2424.
According to an exemplary embodiment, each pin of first and second
sets of pins 2422 and 2424 may comprise a first portion 2420a
configured to couple each of the pins to the openings 2414 and a
second portion 2420b configured to engage base 1010 (see FIGS. 8B
and 8E). According to an exemplary embodiment, second portion 2420b
may be substantially spherical.
[0192] According to an exemplary embodiment as shown schematically
in FIG. 8D, cover 2400 may be formed by an extrusion process. A
first polymer material may be extruded through a first extrusion
die D41 in a direction substantially perpendicular to a direction
of travel of the cover 2400 when cover 2400 is coupled to base 1010
to form top layer 2410. A second polymer material may be extruded
through a second extrusion die D42 in a direction substantially
perpendicular to a direction of travel of cover 2400 when cover
2400 is coupled to base 1010 to form bottom layer 2415. As shown
schematically in FIG. 8D, first and second extrusion dies D41 and
D42 may be configured to allow the first and second polymer
materials to pass through the cut out sections (see portions of
FIG. 8D without cross hatching). Once the first and second polymer
materials pass through first and second extrusion dies D41 and D42
the first and second polymer materials may begin to dry and harden
on the opposite side of first and second extrusion dies D41 and D42
into top and bottom layers 2410 and 2415. According to an exemplary
embodiment, extruding the first polymer material through first
extrusion die D41 may occur simultaneously with extruding the
second polymer material through second extrusion die D42. According
to an exemplary embodiment, bottom layer 2415 may be bonded to top
layer 2410 during the extrusion process.
[0193] According to an exemplary embodiment as shown schematically
in FIG. 8E, pins 2420 may be inserted into openings 2414 of bonded
top and bottom layers 2410 and 2415 to form a core and an extension
2400e. According to an exemplary embodiment, the core may comprise
a first thickness and extension 2400e may comprise a second
thickness less than the first thickness. According to an exemplary
embodiment, extension 2400e may comprise a portion of pins
2420.
[0194] According to an exemplary embodiment as shown schematically
in FIG. 8F, door/cover 2400 may be configured to engage with base
1010 to facilitate movement of cover 2400 relative to base 1010
between a closed position and an open position. Extension 2400e may
be configured to engage base 1010 and the core may be configured to
extend between first wall 1012 and second wall 2014 (see FIG. 2E).
According to an exemplary embodiment, pins 2420 may be configured
to engage with base 1010. According to an exemplary embodiment,
visible surface 2400v, which may be substantially flat and smooth
as a result of the extrusion process, may comprise a soft to touch
feel from a finger F in comparison to bottom layer 2415 as a result
of the visible surface 2400v being formed by the first polymer and
bottom layer 2415 being formed by the second polymer material.
[0195] According to an exemplary embodiment as shown schematically
in FIGS. 9A to 9C, a cover 2500 (e.g. provided by or as a door,
tambour door, door assembly, shade, blind, roller blind, etc.) is
shown. As shown schematically in FIGS. 9A to 9C, cover 2500 may
comprise a visible surface 2500v, a mounting aperture 2509, a top
layer 2510, a bottom layer 2515 (e.g. substrate, layer, platform,
carrier, structure, etc.), and pins 2520 (e.g. extensions,
projections, pegs, posts, features, etc.). As shown schematically
in FIGS. 9B and 9C, visible surface 2500v and mounting aperture
2509 may be integrated with top layer 2510. According to an
exemplary embodiment, mounting aperture 2509 may be configured to
receive a handle or similar structure to help facilitate movement
of cover 2500 from the closed position to the open position when
cover 2500 is coupled to base 1010. As shown schematically in FIG.
9C, bottom layer 2515 may comprise a series of substantially
parallel ribs 2511 and protrusions 2514. According to an exemplary
embodiment, substantially parallel ribs 2511 may be configured to
move relative to one another to facilitate bending of cover 2500.
According to an exemplary embodiment, top layer 2510 may be
comprised of a first material and bottom layer 2515 may be
comprised of a second material different than the first
material.
[0196] According to an exemplary embodiment, pins 2520 may be
configured to be coupled to bottom layer 2515 at protrusions 2514
(see FIGS. 9B and 9H). According to an exemplary embodiment as
shown schematically in FIG. 9C, substantially parallel ribs 2511
may be configured in a tear drop shape. According to an exemplary
embodiment, pins 2520 may comprise a first set of pins 2522 and a
second set of pins 2524. According to an exemplary embodiment, each
pin of first and second sets of pins 2522 and 2524 may comprise a
first portion 2520a configured to couple each of the pins to the
protrusions 2514 and a second portion 2520b configured to engage
base 1010 (see FIGS. 9B and 9H). According to an exemplary
embodiment, second portion 2520b may be substantially
spherical.
[0197] According to an exemplary embodiment as shown schematically
in FIGS. 9D, 9E, and 9G, door/cover 2500 may be formed by a
combination of an extrusion process, a cutting process, and a
molding process. A first polymer material may be extruded through a
first extrusion die D51 in a direction substantially perpendicular
to a direction of travel of the cover 2500 when cover 2500 is
coupled to base 1010 to form top layer 2510. A second polymer
material may be extruded through a second extrusion die D52 in a
direction substantially perpendicular to a direction of travel of
cover 2500 when cover 2500 is coupled to base 1010 to form bottom
layer 2515 (e.g. substrate, layer, platform, carrier, structure,
etc.). As shown schematically in FIG. 9D, first and second
extrusion dies D51 and D52 may be configured to allow the first and
second polymer materials to pass through the cut out sections (see
portions of FIG. 9D without cross hatching). Once the first and
second polymer materials pass through first and second extrusion
dies D51 and D52, the first and second polymer materials may begin
to solidify (e.g. form, set/cure, dry and harden, etc.) on the
opposite side of first and second extrusion dies D51 and D52 into
top and bottom layers 2510 and 2515. According to an exemplary
embodiment, extruding the first polymer material through first
extrusion die D51 may occur simultaneously with extruding the
second polymer material through second extrusion die D52. According
to an exemplary embodiment, bottom layer 2515 may be bonded to top
layer 2510 during the extrusion process.
[0198] According to an exemplary embodiment as shown schematically
in FIG. 9E, bonded together top and bottom layers 2510 and 2520 may
be cut with cutting tool CT to cut away portions 2500b to form
protrusions 2514. A mold M1 may be coupled to protrusions 2514.
Using mold M1, pins 2520 may be over-molded directly on to
protrusions 2514 so as to divide top and bottom layers 2510 and
2520 into a core and an extension 2500e (see FIG. 9H). According to
an exemplary embodiment, the core may comprise a first thickness
and extension 2500e may comprise a second thickness less than the
first thickness. According to an exemplary embodiment, extension
2500e may comprise a portion of pins 2520.
[0199] According to an exemplary embodiment as shown schematically
in FIG. 9H, cover 2500 may be configured to engage with base 1010
to facilitate movement of cover 2500 relative to base 1010 between
a closed position and an open position. Extension 2500e may be
configured to engage base 1010 and the core may be configured to
extend between first wall 1012 and second wall 2014 (see FIG. 2E).
According to an exemplary embodiment, pins 2520 may be configured
to engage with base 1010. According to an exemplary embodiment,
visible surface 2500v, which may be substantially flat and smooth
as a result of the extrusion process, may comprise a soft to touch
feel from a finger F in comparison to bottom layer 2515 as a result
of visible surface 2500v being formed by the first polymer and
bottom layer 2515 being formed by the second polymer material.
[0200] According to an exemplary embodiment shown schematically in
FIGS. 10A to 10C, a cover 2600 (e.g. provided by or as a door,
tambour door, door assembly, shade, blind, roller blind, etc.) is
shown. As shown schematically in FIGS. 10A to 10C, cover 2600 may
comprise a visible surface 2600v, a top layer 2610, and a bottom
layer 2615 (e.g. substrate, layer, platform, carrier, structure,
etc.). As shown schematically in FIGS. 10B and 10C, visible surface
2600v may be integrated with top layer 2610 and may comprise a
curved top profile. As shown schematically in FIG. 10C, top layer
2610 may comprise a series of substantially parallel ribs 2611.
According to an exemplary embodiment, substantially parallel ribs
2611 may be configured to support top layer 2610. According to an
exemplary embodiment, bottom layer 2615 may comprise a set of pins
2620 that may be configured to facilitate bending of cover 2600.
According to an exemplary embodiment, bottom layer 2615 may
comprise a symmetrical form (e.g. halves, etc.) that may be bonded
to opposed sides of top layer 2610. According to an exemplary
embodiment, top layer 2610 may be comprised of a first material and
bottom layer 2615 may be comprised of a second material different
than the first material.
[0201] According to an exemplary embodiment as shown schematically
in FIGS. 10D and 10E, cover 2600 may be formed by a combination of
an extrusion process and a cutting process (e.g. employing tooling,
fixtures, etc.). A first polymer material may be extruded through a
first extrusion die D61 in a direction substantially parallel to a
direction of travel of the cover 2600 when cover 2600 is coupled to
base 1010 to form top layer 2610. A second polymer material may be
extruded through a second extrusion die D62 in a direction
substantially parallel to a direction of travel of cover 2600 when
cover 2600 is coupled to base 1010 to form bottom layer 2615. As
shown schematically in FIG. 10D, first and second extrusion dies
D61 and D62 may be configured to allow the first and second polymer
materials to pass through the cut out sections (see portions of
FIG. 10D without cross hatching). Once the first and second polymer
materials pass through first and second extrusion dies D61 and D62,
the first and second polymer materials may begin to solidify (e.g.
form, set/cure, dry and harden, etc.) on the opposite side of first
and second extrusion dies D61 and D62 into a precursor (e.g.
section or segment of cover/door) 601 comprising top and bottom
layers 2610 and 2615. According to an exemplary embodiment,
extruding the first polymer material through first extrusion die
D61 may occur simultaneously with extruding the second polymer
material through second extrusion die D62. According to an
exemplary embodiment, bottom layer 2615 may be bonded to top layer
2610 during the extrusion process.
[0202] As shown schematically in FIG. 10D, cover precursor 601 may
be cut with cutting tool CT to cut away portions of cover precursor
601 to form pins 2620 in bottom layer 2615. According to an
exemplary embodiment first portions 2620a of pins 2620 may be
formed by cutting tool CT cutting away portions of bottom layer
2615 to form second portions 2620b of pins 2620 (e.g. extensions,
projections, pegs, posts, features, etc.). As shown schematically
in FIG. 10F, door/cover 2600 may be configured to engage with base
1010 to facilitate movement of cover 2600 relative to base 1010
between a closed position and an open position. According to an
exemplary embodiment, visible surface 2600v, which may be
substantially flat and smooth as a result of the extrusion process,
may comprise a soft to touch feel from a finger F in comparison to
bottom layer 2615 as a result of visible surface 2600v being formed
by the first polymer and bottom layer 2615 being formed by the
second polymer material.
[0203] According to an exemplary embodiment as shown schematically
in FIGS. 11A to 11B, a cover 2700 (e.g. provided by or as a door,
tambour door, door assembly, shade, blind, roller blind, etc.) is
shown. As shown schematically in FIGS. 11A to 11C, cover 2700 may
comprise a visible surface 2700v, a top layer 2710, and a bottom
layer 2715 (e.g. substrate, layer, platform, carrier, structure,
etc.). As shown schematically in FIGS. 11B and 11C, visible surface
2700v may be integrated with top layer 2710 and may comprise a
curved top profile. As shown schematically in FIG. 11C, top layer
2710 may comprise a variable thickness. According to an exemplary
embodiment top layer 2710 may have a maximum thickness t2 at the
center, a minimum thickness at the edge, and an intermediate
thickness t1 in between the center and the edge. According to an
exemplary embodiment, bottom layer 2715 may comprise a set of pins
2720 that may be configured to facilitate bending of cover 2700.
According to an exemplary embodiment, top layer 2710 may be
comprised of a first material and bottom layer 2715 may be
comprised of a second material different than the first
material.
[0204] According to an exemplary embodiment as shown schematically
in FIGS. 11D and 11E, cover 2700 may be formed by a combination of
an extrusion process and a cutting process (e.g. employing tooling,
fixtures, etc.). A first polymer material may be extruded through a
first extrusion die D71 in a direction substantially parallel to a
direction of travel of the cover 2700 when cover 2700 is coupled to
base 1010 to form top layer 2710. A second polymer material may be
extruded through a second extrusion die D72 in a direction
substantially parallel to a direction of travel of cover 2700 when
cover 2700 is coupled to base 1010 to form bottom layer 2715. As
shown schematically in FIG. 11D, first and second extrusion dies
D71 and D72 may be configured to allow the first and second polymer
materials to pass through the cut out sections (see portions of
FIG. 11D without cross hatching). Once the first and second polymer
materials pass through first and second extrusion dies D71 and D72,
the first and second polymer materials may begin to solidify (e.g.
form, set/cure, dry and harden, etc.) on the opposite side of first
and second extrusion dies D71 and D72 into a precursor (e.g.
section or segment of cover/door) 701 comprising top and bottom
layers 2710 and 2715. According to an exemplary embodiment,
extruding the first polymer material through first extrusion die
D71 may occur simultaneously with extruding the second polymer
material through second extrusion die D72. According to an
exemplary embodiment, bottom layer 2715 may be bonded to top layer
2710 during the extrusion process.
[0205] According to an exemplary embodiment as shown schematically
in FIG. 11D, cover precursor 701 may be cut with cutting tool CT to
cut away portions of cover precursor 701 to form pins 2720 in
bottom layer 2715. According to an exemplary embodiment, cutting
tool CT may periodically cut in a direction parallel to a front
face of cover precursor 701. As shown schematically in FIG. 11F,
door/cover 2700 may be configured to engage with base 1010 to
facilitate movement of cover 2700 relative to base 1010 between a
closed position and an open position. According to an exemplary
embodiment, visible surface 2700v, which may be substantially flat
and smooth as a result of the extrusion process, may comprise a
soft to touch feel from a finger F in comparison to bottom layer
2715 as a result of visible surface 2700v being formed by the first
polymer and bottom layer 2715 being formed by the second polymer
material.
[0206] According to an exemplary embodiment as shown schematically
in FIGS. 12A to 12C, a cover 100 (e.g. provided by or as a door,
tambour door, door assembly, shade, blind, roller blind, etc.) is
shown. As shown schematically in FIGS. 12A to 12C, cover 100 may
comprise a visible surface 100v, a mounting aperture 109, a
substrate 110, and pins 120 (e.g. extensions, projections, pegs,
posts, features, etc.). As shown schematically in FIG. 12C,
substrate 110 may comprise a series of substantially parallel ribs
111. According to an exemplary embodiment, mounting aperture 109
may be configured to receive a handle or similar structure to help
facilitate movement of cover 100 from the closed position to the
open position when cover 100 is coupled to base 1010. Substantially
parallel ribs 111 may comprise apertures 112. According to an
exemplary embodiment, substantially parallel ribs 111 may be
configured to move relative to one another to facilitate bending of
cover 100. According to an exemplary embodiment, pins 120 may be
configured to be bonded to substrate 110 at each of the
substantially parallel ribs 120. According to an exemplary
embodiment, pins 120 may be formed in a single monolithic structure
with the substrate 110.
[0207] According to an exemplary embodiment as shown schematically
in FIGS. 12D and 12E, door/cover 100 may be formed by a combination
of an extrusion process and a cutting process (e.g. employing
tooling, fixtures, etc.). A polymer material may be extruded
through a tool/machine shown as comprising an extrusion die D1 in a
direction substantially perpendicular to a direction of travel of
the cover 100 when cover 100 is coupled to base 1010. As shown
schematically in FIG. 12D, extrusion die D1 may be configured to
allow the polymer material to pass through the cut out sections
(see portions of FIG. 12D without cross hatching). Once the polymer
material passes through extrusion die D1 the material may begin to
solidify (e.g. form, set/cure, dry and harden, etc.) on the
opposite side of extrusion die D1 into a precursor (e.g. section or
segment of cover/door) 10 with a shape that partially matches a
side profile of substrate 110. According to an exemplary
embodiment, pins 120 may be bonded to substrate 110 during the
extrusion process.
[0208] According to an exemplary embodiment as shown schematically
in FIG. 12E, cover precursor 10 may include visible surface 100v
which may be substantially flat and smooth as a result of the
extrusion process and the presence of the apertures 112. Cover
precursor 10 may then be cut with cutting tool CT to cut away
portions of cover precursor 10 to form substrate 110 into a core
and an extension 100e. According to an exemplary embodiment,
cutting tool CT may cut in a U-shaped pattern to form extension
100e. According to an exemplary embodiment, the core may comprise a
first thickness and extension 100e may comprise a second thickness
less than the first thickness. According to an exemplary
embodiment, extension 100e may comprise a portion of pins 120.
[0209] According to an exemplary embodiment as shown schematically
in FIG. 12F, door/cover 100 may be configured to engage with base
1010 to facilitate movement of cover 100 relative to base 1010
between a closed position and an open position. Extension 100e may
be configured to engage base 1010 and the core may be configured to
extend between first wall 1012 and second wall 1014 (see FIG. 2E).
According to an exemplary embodiment, pins 120 may be configured to
engage with base 1010.
[0210] According to an exemplary embodiment as shown schematically
in FIGS. 13A to 13C, a cover 200 (e.g. provided by or as a door,
tambour door, door assembly, shade, blind, roller blind, etc.) is
shown. As shown schematically in FIGS. 13A to 13C, cover 200 may
comprise a visible surface 200v, a mounting aperture 209, a
substrate 210, and pins 220 (e.g. extensions, projections, pegs,
posts, features, etc.). As shown schematically in FIG. 13C,
substrate 210 may comprise a series of substantially parallel ribs
211 and openings 214. According to an exemplary embodiment,
mounting aperture 209 may be configured to receive a handle or
similar structure to help facilitate movement of cover 200 from the
closed position to the open position when cover 200 is coupled to
base 1010. Substantially parallel ribs 211 may comprise apertures
212 between viable surface 200v and openings 214. According to an
exemplary embodiment, substantially parallel ribs 211 may be
configured to move relative to one another to facilitate bending of
cover 200. According to an exemplary embodiment, pins 220 may be
configured to be coupled to substrate 210 at openings 214 (see
FIGS. 13B and 13E). According to an exemplary embodiment, pins 220
may be configured to pass entirely though substrate 210.
[0211] According to an exemplary embodiment, cover 200 may be
formed by an extrusion process. A polymer material may be extruded
through a tool/machine shown as comprising an extrusion die D2 in a
direction substantially perpendicular to a direction of travel of
the cover 200 when cover 200 is coupled to base 1010. As shown
schematically in FIG. 13D, extrusion die D2 may be configured to
allow the polymer material to pass through the cut out sections
(see portions of FIG. 13D without cross hatching). Once the polymer
passes through extrusion die D2 the material may begin to solidify
(e.g. form, set/cure, dry and harden, etc.) on the opposite side of
extrusion die D2 into substrate 210. According to an exemplary
embodiment, visible surface 200v may be substantially flat and
smooth as a result of the extrusion process and the presence of
apertures 212.
[0212] According to an exemplary embodiment as shown schematically
in FIG. 13E, pins 220 may be inserted into openings 214 of
substrate 210 to form a core and an extension 200e. According to an
exemplary embodiment, the core may comprise a first thickness and
extension 200e may comprise a second thickness less than the first
thickness. According to an exemplary embodiment, extension 200e may
comprise a portion of pins 220.
[0213] According to an exemplary embodiment as shown schematically
in FIG. 13F, door/cover 200 may be configured to engage with base
1010 to facilitate movement of cover 200 relative to base 1010
between a closed position and an open position. Extension 200e may
be configured to engage base 1010 and the core may be configured to
extend between first wall 1012 and second wall 1014 (see FIG. 2E).
According to an exemplary embodiment, pins 220 may be configured to
engage with base 1010.
[0214] According to an exemplary embodiment as shown schematically
in FIGS. 14A to 14C, a cover 300 (e.g. provided by or as a door,
tambour door, door assembly, shade, blind, roller blind, etc.) is
shown. As shown schematically in FIGS. 14A to 14C, cover 300 may
comprise a visible surface 300v, a substrate 310, and pins 320
(e.g. extensions, projections, pegs, posts, features, etc.). As
shown schematically in FIG. 14C, substrate 310 may comprise a first
portion 310a, a second portion 310b (see FIG. 14E), a series of
substantially parallel ribs 311 and openings 314. According to an
exemplary embodiment as shown schematically in FIG. 14E, first
portion 310a may comprise a top surface and a bottom surface and
second portion 310b may comprise a top surface 310s. According to
an exemplary embodiment, first portion 310a may be hinged to second
portion 310b. According to an exemplary embodiment, the bottom
surface of first portion 310a may be adjacent top surface 310s of
the second portion. According to an exemplary embodiment, the
bottom surface of first portion 310a may be bonded to top surface
310s of the second portion. According to an exemplary embodiment,
the top surface of first portion 310a may comprise visible surface
300v and may face an interior of a vehicle.
[0215] According to an exemplary embodiment, substantially parallel
ribs 311 may be configured to move relative to one another to
facilitate bending of cover 300. According to an exemplary
embodiment, pins 320 may be configured to be coupled to substrate
310 at openings 314 (see FIGS. 14B and 14F). According to an
exemplary embodiment, pins 320 may comprise a first set of pins 322
and a second set of pins 324. According to an exemplary embodiment,
each pin of first and second sets of pins 322 and 324 may comprise
a first portion configured to couple each of the pins to openings
314 and a second portion configured to engage base 1010 (see FIGS.
14F and 14G).
[0216] According to an exemplary embodiment, cover 300 may be
formed by an extrusion process. A polymer material may be extruded
through a tool/machine shown as comprising an extrusion die D3 in a
direction substantially perpendicular to a direction of travel of
the cover 300 when cover 300 is coupled to base 1010. As shown
schematically in FIG. 14D, extrusion die D3 may be configured to
allow the polymer material to pass through the cut out sections
(see portions of FIG. 14D without cross hatching). Once the polymer
passes through extrusion die D3 the material may begin to solidify
(e.g. form, set/cure, dry and harden, etc.) on the opposite side of
extrusion die D3 into substrate 310.
[0217] As shown schematically in FIG. 14E, first portion 310 may be
rotated in a direction such that the bottom surface of first
portion 310a may be adjacent to the top surface 310s of second
portion 310b. According to an exemplary embodiment, the bottom
surface of first portion 310a may be bonded to top surface 310s of
the second portion. As shown schematically in FIG. 14F, pins 320
may be inserted into openings 314 of substrate 310 to form a core
and an extension 300e. According to an exemplary embodiment, the
core may comprise a first thickness and extension 300e may comprise
a second thickness less than the first thickness. According to an
exemplary embodiment, extension 300e may comprise a portion of pins
320.
[0218] According to an exemplary embodiment as shown schematically
in FIG. 14G, door/cover 300 may be configured to engage with base
1010 to facilitate movement of cover 300 relative to base 1010
between a closed position and an open position. Extension 300e may
be configured to engage base 1010 and the core may be configured to
extend between first wall 1012 and second wall 1014 (see FIG. 2E).
According to an exemplary embodiment, pins 320 may be configured to
engage with base 1010.
[0219] According to an exemplary embodiment as shown schematically
in FIGS. 15A to 15C, a cover 400 (e.g. provided by or as a door,
tambour door, door assembly, shade, blind, roller blind, etc.) is
shown. As shown schematically in FIGS. 15A to 15C, cover 400 may
comprise a visible surface 400v, a substrate 410, and pins 420
(e.g. extensions, projections, pegs, posts, features, etc.). As
shown schematically in FIG. 15C, substrate 410 may comprise a
series of substantially parallel ribs 411, openings 414, and
notches 416. According to an exemplary embodiment, substantially
parallel ribs 411 may be configured to move relative to one another
to facilitate bending of cover 400. According to an exemplary
embodiment as shown schematically in FIG. 15E, notches 416 may be
between the substantially parallel ribs 411 and may be configured
to further facilitate bending of cover 400 to a greater degree than
the arrangement of the substantially parallel ribs 411 may provide
alone. According to an exemplary embodiment, notches 416 may be
omitted and bending of cover 400 may be facilitated solely by the
configuration of substantially parallel ribs 411. According to an
exemplary embodiment, pins 420 may be configured to be coupled to
substrate 410 at openings 414 (see FIGS. 15B and 15F). According to
an exemplary embodiment, pins 420 may comprise a first set of pins
422 and a second set of pins 424. According to an exemplary
embodiment, each pin of first and second sets of pins 422 and 424
may comprise a first portion configured to couple each of the pins
to openings 414 and a second portion configured to engage base 1010
(see FIGS. 15F and 15G).
[0220] According to an exemplary embodiment, cover 400 may be
formed by an extrusion process. A polymer material may be extruded
through a tool/machine shown as comprising an extrusion die D4 in a
direction substantially perpendicular to a direction of travel of
cover 400 when cover 400 is coupled to base 1010. As shown
schematically in FIG. 15D, extrusion die D4 may be configured to
allow the polymer material to pass through the cut out sections
(see portions of FIG. 15D without cross hatching). Once the polymer
material passes through extrusion die D4 the polymer material may
begin to solidify (e.g. form, set/cure, dry and harden, etc.) on
the opposite side of extrusion die D4 into substrate 410. According
to an exemplary embodiment, visible surface 400v may be
substantially flat and smooth as a result of the extrusion
process.
[0221] According to an exemplary embodiment as shown schematically
in FIG. 15F, pins 420 may be inserted into openings 414 of
substrate 410 to form a core and an extension 400e. According to an
exemplary embodiment, the core may comprise a first thickness and
extension 400e may comprise a second thickness less than the first
thickness. According to an exemplary embodiment, extension 400e may
comprise a portion of pins 420.
[0222] According to an exemplary embodiment as shown schematically
in FIG. 15G, door/cover 400 may be configured to engage with base
1010 to facilitate movement of cover 400 relative to base 1010
between a closed position and an open position. Extension 400e may
be configured to engage base 1010 and the core may be configured to
extend between first wall 1012 and second wall 1014 (see FIG. 2E).
According to an exemplary embodiment, pins 420 may be configured to
engage with base 1010.
[0223] According to an exemplary embodiment as shown schematically
in FIGS. 16A to 16C, a cover 500 (e.g. provided by or as a door,
tambour door, door assembly, shade, blind, roller blind, etc.) is
shown. As shown schematically in FIGS. 16A to 16C, cover 500 may
comprise a visible surface 500v, a substrate 510, and pins 520
(e.g. extensions, projections, pegs, posts, features, etc.). As
shown schematically in FIG. 16C, substrate 510 may comprise a
series of substantially parallel ribs 511 and openings 514.
According to an exemplary embodiment, substantially parallel ribs
511 may be configured to move relative to one another to facilitate
bending of cover 500. According to an exemplary embodiment as shown
schematically in FIGS. 16C and 16E, substantially parallel ribs 511
may be configured in a tear drop shape and openings 514 may be
configured in a tear drop shape to optimize surface contact with
pins 520. According to an exemplary embodiment, pins 520 may be
configured to be coupled to substrate 510 at openings 514 (see
FIGS. 16B and 16F). According to an exemplary embodiment, pins 520
may comprise a first set of pins 522 and a second set of pins 524.
According to an exemplary embodiment, each pin of first and second
sets of pins 522 and 524 may comprise a first portion 520a
configured to couple each of the pins to openings 514 and a second
portion 520b configured to engage base 1010 (see FIGS. 16F and
16G). According to an exemplary embodiment, second portion 520b may
be substantially spherical.
[0224] According to an exemplary embodiment, cover 500 may be
formed by an extrusion process. A polymer material may be extruded
through a tool/machine shown as comprising an extrusion die D5 in a
direction substantially perpendicular to a direction of travel of
cover 500 when cover 500 is coupled to base 1010. As shown
schematically in FIG. 16D, extrusion die D5 may be configured to
allow the polymer material to pass through the cut out sections
(see portions of FIG. 16D without cross hatching). Once the polymer
material passes through extrusion die D5 the polymer material may
begin to solidify (e.g. form, set/cure, dry and harden, etc.) on
the opposite side of extrusion die D5 into substrate 510. According
to an exemplary embodiment, visible surface 500v may be
substantially flat and smooth as a result of the extrusion
process.
[0225] According to an exemplary embodiment as shown schematically
in FIG. 16F, pins 520 may be inserted into openings 514 of
substrate 510 to form a core and an extension 500e. According to an
exemplary embodiment, the core may comprise a first thickness and
extension 500e may comprise a second thickness less than the first
thickness. According to an exemplary embodiment, extension 500e may
comprise a portion of pins 520.
[0226] According to an exemplary embodiment as shown schematically
in FIG. 16G, door/cover 500 may be configured to engage with base
1010 to facilitate movement of cover 500 relative to base 1010
between a closed position and an open position. Extension 500e may
be configured to engage base 1010 and the core may be configured to
extend between first wall 1012 and second wall 1014 (see FIG. 2E).
According to an exemplary embodiment, pins 520 may be configured to
engage with base 1010.
[0227] According to an exemplary embodiment shown schematically in
FIGS. 17A to 17C, a cover 600 (e.g. provided by or as a door,
tambour door, door assembly, shade, blind, roller blind, etc.) is
shown. As shown schematically in FIGS. 17A to 17C, cover 600 may
comprise a visible surface 600v, a substrate 610, and pins 620
(e.g. extensions, projections, pegs, posts, features, etc.). As
shown schematically in FIG. 17C, substrate 610 may comprise a
series of substantially parallel ribs 611 and protrusions 614.
According to an exemplary embodiment, substantially parallel ribs
611 may be configured to move relative to one another to facilitate
bending of cover 600. According to an exemplary embodiment as shown
schematically in FIG. 17C, substantially parallel ribs 611 may be
configured in a tear drop shape. According to an exemplary
embodiment, pins 620 may be configured to be coupled to substrate
610 at protrusions 614 (see FIGS. 17B and 17G). According to an
exemplary embodiment, pins 620 may comprise a first set of pins 622
and a second set of pins 624. According to an exemplary embodiment,
each pin of first and second sets of pins 622 and 624 may comprise
a first portion 620a configured to couple each of the pins to
openings 614 and a second portion 620b configured to engage base
1010 (see FIG. 17H). According to an exemplary embodiment, the
second portion 620b may be substantially spherical.
[0228] According to an exemplary embodiment as shown schematically
in FIGS. 17D, 17E and 17G, door/cover 600 may be formed by a
combination of an extrusion process, a cutting process, and a
molding process. A polymer material may be extruded through a
tool/machine shown as comprising an extrusion die D6 in a direction
substantially perpendicular to a direction of travel of cover 600
when cover 600 is coupled to base 1010. As shown schematically in
FIG. 17D, extrusion die D6 may be configured to allow the polymer
material to pass through the cut out sections (see portions of FIG.
17D without cross hatching). Once the polymer material passes
through extrusion die D6 the polymer material may begin to solidify
(e.g. form, set/cure, dry and harden, etc.) on the opposite side of
extrusion die D6 into a precursor (e.g. section or segment of
cover/door) 60 with a shape that generally matches substrate 610.
According to an exemplary embodiment, visible surface 600v may be
substantially flat and smooth as a result of the extrusion
process.
[0229] According to an exemplary embodiment as shown schematically
in FIG. 17E, cover precursor 60 may be cut with cutting tool CT to
cut away portions of cover precursor 60 to form substrate 610
including protrusions 614. A mold M1 may be coupled to protrusions
614. Using mold M1, pins 620 may be over-molded directly on to
protrusions 614 so as to divide substrate 610 into a core and an
extension 600e (see FIG. 17H). According to an exemplary
embodiment, the core may comprise a first thickness and extension
600e may comprise a second thickness less than the first thickness.
According to an exemplary embodiment, extension 600e may comprise a
portion of pins 620.
[0230] According to an exemplary embodiment as shown schematically
in FIG. 17H, cover 600 may be configured to engage with base 1010
to facilitate movement of cover 600 relative to base 1010 between a
closed position and an open position. Extension 600e may be
configured to engage base 1010 and the core may be configured to
extend between first wall 1012 and second wall 1014 (see FIG. 2E).
According to an exemplary embodiment, pins 620 may be configured to
engage with base 1010.
[0231] According to an exemplary embodiment as shown schematically
in FIGS. 18A to 18B, a cover 700 (e.g. provided by or as a door,
tambour door, door assembly, shade, blind, roller blind, etc.) is
shown. As shown schematically in FIGS. 18A to 18B, cover 700 may
comprise a visible surface 700v, a substrate 710, and pins 720
(e.g. extensions, projections, pegs, posts, features, etc.). Pins
720 may be configured to facilitate bending of cover 700.
[0232] According to an exemplary embodiment as shown schematically
in FIGS. 18C and 18D, cover 700 may be formed by a combination of
an extrusion process and a cutting process (e.g. employing tooling,
fixtures, etc.). A polymer material may be extruded through a
tool/machine shown as comprising an extrusion die D7 in a direction
substantially parallel to a direction of travel of cover 700 when
cover 700 is coupled to base 1010. As shown schematically in FIG.
18C, extrusion die D7 may be configured to allow the polymer
material to pass through the cut out sections (see portions of FIG.
18C without cross hatching). Once the polymer material passes
through extrusion die D7 the polymer material may begin to solidify
(e.g. form, set/cure, dry and harden, etc.) on the opposite side of
extrusion die D7 into a precursor (e.g. section or segment of
cover/door) 70 with a shape that generally matches a front view
profile of substrate 710. According to an exemplary embodiment,
visible surface 700v may be substantially flat and smooth as a
result of the extrusion process.
[0233] According to an exemplary embodiment as shown schematically
in FIG. 18D, cover precursor 70 may be cut with cutting tool CT to
cut away portions of cover precursor 70 to form pins 720. According
to an exemplary embodiment first portions 720a of pins 720 may be
formed by cutting tool CT cutting away portions of substrate 710 to
form second portions 720b of pins 720. As shown schematically in
FIG. 18F, door/cover 700 may be configured to engage with base 1010
to facilitate movement of cover 700 relative to base 1010 between a
closed position and an open position. According to an exemplary
embodiment, first portions 720a may be configured to engage with
base 1010.
[0234] It is important to note that the present inventions (e.g.
inventive concepts, etc.) have been described in the specification
and/or illustrated in the FIGURES of the present patent document
according to exemplary embodiments; the embodiments of the present
inventions are presented by way of example only and are not
intended as a limitation on the scope of the present inventions.
The construction and/or arrangement of the elements of the
inventive concepts embodied in the present inventions as described
in the specification and/or illustrated in the FIGURES is
illustrative only. Although exemplary embodiments of the present
inventions have been described in detail in the present patent
document, a person of ordinary skill in the art will readily
appreciate that equivalents, modifications, variations, etc. of the
subject matter of the exemplary embodiments and alternative
embodiments are possible and contemplated as being within the scope
of the present inventions; all such subject matter (e.g.
modifications, variations, embodiments, combinations, equivalents,
etc.) is intended to be included within the scope of the present
inventions. It should also be noted that various/other
modifications, variations, substitutions, equivalents, changes,
omissions, etc. may be made in the configuration and/or arrangement
of the exemplary embodiments (e.g. in concept, design, structure,
apparatus, form, assembly, construction, means, function, system,
process/method, steps, sequence of process/method steps, operation,
operating conditions, performance, materials, composition,
combination, etc.) without departing from the scope of the present
inventions; all such subject matter (e.g. modifications,
variations, embodiments, combinations, equivalents, etc.) is
intended to be included within the scope of the present inventions.
The scope of the present inventions is not intended to be limited
to the subject matter (e.g. details, structure, functions,
materials, acts, steps, sequence, system, result, etc.) described
in the specification and/or illustrated in the FIGURES of the
present patent document. It is contemplated that the claims of the
present patent document will be construed properly to cover the
complete scope of the subject matter of the present inventions
(e.g. including any and all such modifications, variations,
embodiments, combinations, equivalents, etc.); it is to be
understood that the terminology used in the present patent document
is for the purpose of providing a description of the subject matter
of the exemplary embodiments rather than as a limitation on the
scope of the present inventions.
[0235] It is also important to note that according to exemplary
embodiments the present inventions may comprise conventional
technology (e.g. as implemented and/or integrated in exemplary
embodiments, modifications, variations, combinations, equivalents,
etc.) or may comprise any other applicable technology (present
and/or future) with suitability and/or capability to perform the
functions and processes/operations described in the specification
and/or illustrated in the FIGURES. All such technology (e.g. as
implemented in embodiments, modifications, variations,
combinations, equivalents, etc.) is considered to be within the
scope of the present inventions of the present patent document.
* * * * *