KR100776077B1 - Vehicle component and method for making a vehicle panel - Google Patents

Abstract

A method of forming a panel is disclosed. The method includes forming a flexible skin 22, coupling the compressible material 24 to the skin 22, placing the skin 22 and the compressible material 24 in a mold, and compressing the material. Forming a rigid substrate 20 to surround 24 and skin 22 to form a first flexible zone 12 in which compressible material 24 is disposed between skin 22 and substrate 20, The first soft zone 12 includes a step defined by the compressible material 24.

Vehicle panel manufacturing methods, flexible skins, compressible materials, rigid substrates, flexible zones

Description

How to make vehicle parts and vehicle panels {VEHICLE COMPONENT AND METHOD FOR MAKING A VEHICLE PANEL}

The present invention relates to a vehicle trim panel. More specifically, the invention relates to a vehicle trim panel, for example for a door, with an integral flexible armrest.

The present invention generally relates to the field of parts such as panels or other structures for use in vehicles (eg, cars, trucks, etc. cars, airplanes, ships, etc.). More specifically, the present invention relates to interior panels or structures for vehicles or other uses, comprising one or more relatively soft (eg, padded or cushioned) portions.

Vehicle interior components with pads or cushions, such as panels (eg, instrument panels, door panels, etc.) typically have a substrate made of a relatively rigid material, a relatively soft core (eg, a foam core), and an exterior face or skin. Include as. For example, the vehicle door panel may have a cushion to provide additional comfort for the driver of the vehicle when a part of the driver's body contacts or contacts the door panel. While various methods of providing such a cushion are known in the art, such known methods do not provide features and / or a combination of features with particular advantages.

For example, one of the difficulties in producing panels with cushion portions is that it may be difficult to optimize the position of the cushion portions so that the cushion portions are provided only in areas where they are in direct contact (eg abutment) by a person. For example, certain areas of in-vehicle trim panels are not contacted by passengers as they are on a door panel near the floor of the vehicle. There will be little or no reason to provide a cushion portion of the door panel in these areas. In addition, providing cushion portions or zones in areas that do not need to do so can add unnecessary cost (ie, material, labor and equipment) and add surplus weight to the vehicle.

In order to provide a local cushioning part for the interior vehicle parts, one known method involves coupling the cushioning part to a rigid part. For example, a relatively rigid panel (eg, a door panel) may have joined parts comprising a relatively rigid substrate, a relatively soft skin, and a foam interior portion. One of the difficulties of such a method is that such a method requires the use of additional components (e.g. bolts or other joining tools for securing the panel substrate to the substrate of the cushioning portion, additional substrates, etc.), which is characterized by weight and It adds all of the costs.

Accordingly, there is a need to provide a method of producing parts such as panels or other structures for vehicle use that include relatively soft portions or sections. There is also a need to provide parts with local cushioning zones optimized based on locations likely to be contacted by the vehicle driver or others. There is also a need to provide parts with local cushioning zones that require less material and have reduced mass than those with conventional cushioning zones. There is also a need to provide an integrally formed vehicle part comprising a local cushion zone. There is also a need to provide a method and component for manufacturing a component that can be manufactured in a relatively simple and efficient manner with reduced manufacturing and material costs. There is also a need to provide a manufacturing method for producing parts having one or more cushion portions utilizing existing equipment.

The present invention relates to a method of forming a panel. The method includes forming a flexible skin, bonding the compressible material to the skin, placing the skin and the compressible material in a mold, and surrounding the compressive material 24 and the skin 22. ) To form a first flexible zone 12 in which a compressible material 24 is disposed between the skin 22 and the substrate 20, the first flexible zone 12 being formed in the compressible material 24. It includes the steps defined by. The substrate may comprise a molded polymeric material, such as a thermoplastic. The skin may comprise thermoplastic olefins and may be formed by trimming and vacuum forming the sheet. Compressible materials can include foam materials such as closed cell foam. The skin can include a flange such that the substrate can be formed to at least partially encapsulate the flange. The second soft zone may be formed as part of a skin in direct contact with the substrate (eg, no compressible material is disposed between the skin and the substrate).

The invention also relates to various features and combinations of features shown and described in the disclosed embodiments.

1 is a perspective view of a door trim panel according to a preferred embodiment.

FIG. 2 is a perspective cross-sectional view of the door trim panel of FIG. 1 along line 2-2. FIG.

3-6 are partial perspective views of the door trim panel of FIG. 2 in various fabrication conditions.

Before describing in detail the numerous preferred, exemplary, and other embodiments of the invention, it is to be understood that the invention is not limited to the details of construction and arrangement of the components shown in the figures or described in the following description. have. The invention may be other embodiments and may be practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

1 and 2 illustrate one exemplary embodiment of a part or assembly, such as a panel or other structures for use in a vehicle (eg, a car, an airplane, a ship, such as a car, truck, bus, etc.). Such parts may be provided in a wide variety of sizes, shapes, and configurations, in accordance with various exemplary embodiments. For example, these parts may be utilized inside the cabin of a vehicle, and may be in the form of door panels, dashboards, instrument panels, consoles, sidewall trims, overhead liners, or other vehicle parts or parts thereof. It can be used as. 1 shows one exemplary embodiment of a door panel 10.

The vehicle part has one or more areas or portions 12 of soft or cushioned, local or separated, in areas contacted by a passenger or other person. For example, a door panel 10 such as that shown in FIG. 1 may be provided with an area that is not normally touched by a passenger without the need to provide cushioning for the entire door (eg, the region of hard plastic 18 in FIG. 1). A cushion is provided in an area 12 (eg, arm rest 14 adjacent to the jaw of window 16) where a part of the passenger's body is likely to contact the door. In this way, the area 12 of the cushion can be optimized based on the typical passenger experience. One of the beneficial features of this method is that the material and manufacturing costs can be reduced and the relatively inefficient way of providing cushions to areas that are not generally contacted by passengers (eg under the arm rest 14) can be ruled out. Is there.

The method of providing a localized zone of soft or cushion 12 in the manner described herein may be utilized to provide parts having a wide variety of configurations. For example, one or more portions 18 (eg, areas, zones, etc.) of hard plastic (eg, bezel, accent, applique, pull cup, etc.) are included. A door panel 10 may be provided. In other examples, complex geometries (eg, ball armrests, x, y, z boundaries, etc.) may be formed. In another example, the door panel 10 may include a stateful (eg, raised) or recessed area of the cushion for improved aesthetics.

According to an exemplary embodiment, the component includes a member or element in the form of a relatively rigid substrate, base, or layer (hereinafter referred to simply as "substrate" 20). The portion or zone 12 having a cushion or pad is located adjacent to or near at least a portion of the substrate 20 and is provided with a filling material provided between or in between the skin 22 and the skin 22 and the substrate 20. 24). According to various example embodiments, it can be seen that all or part of the substrate 20 can have a portion 12 having a cushion or pad provided adjacent to the substrate. For example, according to an exemplary embodiment, the skin 22 is applied adjacent to the substrate 20, and portions of the skin 22 are in direct contact with the substrate 20, while other portions of the skin 22 are in contact with the substrate 20. Can be separated from the substrate by the filling material 24. In this way, optionally varying amounts or degrees of softness or cushion are provided in one or more local zones, while maintaining the feel and appearance of the skin even in areas where no additional cushion of fill material 24 is provided.

According to an exemplary embodiment, the member or element or portion 12 having a relatively cushion or pad is disposed over at least a portion of the substrate 20. Skin 22 forms at least a portion of the exterior surface of the part (eg, the portion visible from the cabin, such as commonly referred to as the "A" side). According to an exemplary embodiment, the portion 26 of the substrate 20 forms part of the outer surface. A boundary 28 between the substrate and the skin may be provided (eg in the form of a seam, interface or seam). Such a boundary 28 can be seen from the exterior face or can be filled with a material to give the part a "seamless" appearance.

According to an exemplary embodiment, the skin 22 is made of a relatively soft or flexible material that includes a polymeric material (eg, thermoplastic olefin (TPO), polyurethane, polyvinylchloride (PVC), etc.). According to other exemplary embodiments, skin 22 may be made of other materials, including fabrics such as cloth, leather, composites, layered materials (eg, leather layers applied over a layer of polymeric material), and the like. have.

According to a preferred embodiment, the skin 22 is provided over the substrate 22 in such a way that the filling material 24 (if any) is positioned between or in between the substrate 20 and at least a portion of the skin 22. According to an exemplary embodiment, portions of skin 22 are provided in direct contact with substrate 20 such that fill material 24 may be positioned between skin 22 and substrate 20 in one or more specific zones. Can be. The particular design chosen may depend on any of a variety of factors, including the desired look and feel of the outer surface of the panel, the cost of materials, ease of manufacture, and the like.

According to an exemplary embodiment, skin 22 may be manufactured or produced utilizing any of a variety of processes. According to a preferred embodiment, the skin 22 (eg, TPO sheet) is thermoformed (eg vacuum formed, pressure molded, etc.) and trimmed to the desired shape or configuration. In a vacuum forming process, a pre-cut or shaped sheet of polymer material is provided to a mold and heated to soften the material. A vacuum is applied to the mold and pulls the softened polymer material towards the wall of the mold. The polymeric material is cooled and retains the shape formed by the mold walls. The formed sheet can also be trimmed to a predetermined size.

According to another embodiment, the skin is subjected to a slush molding process (e.g., a liquid or powdered thermoplastic material is injected into a temperature controlled mold to form a viscous skin adjacent to the mold wall. Removed from the mold and the skin cured and cooled, after which the skin is separated from the mold). According to other embodiments, skin 22 may be fabricated according to a variety of other methods. For example, the skin can be made by an injection molding process, an extrusion process, a casting process (eg, gravity casting), or any other suitable process for forming a polymer skin.

According to an exemplary embodiment where the skin 22 is made of a polymeric material, the skin has a thickness between approximately 0.1 and 2.0 mm, most preferably between approximately 0.8 and 1.0 mm.

Skin 22 may have a size, shape, and configuration that adapts and forms to the features included in substrate 20. The size, shape, and configuration of skin 22 and substrate 20 can have any number of forms, and relatively complex geometries can be formed.

The material (eg, fill material 24) is bonded to (eg, adheres, melts, binds to, joins, attaches, etc.) to skin 22 and is positioned between skin 22 and substrate 24 to serve as filler. Do it. Such materials are intended to serve as relatively soft or cushioning materials that provide the cushion member with a portion of at least relatively soft or cushioning properties. According to a preferred embodiment, the material is a polymeric material such as a foam material (eg urethane foam closed cell foam, open celled foam, etc.).

Substrate 20 may be made of any suitable material, including any of a variety of polymers (eg, polypropylene, polyethylene, interpolymers, etc.). Substrate 20 may be formed of any of a wide variety of shapes, sizes, and configurations (eg, FIG. 1 illustrates door panel 10 according to an exemplary embodiment having local cushioning zones), Various other features may be included (eg, openings for door locks and handles, molded-in designs, and the like). Substrate 20 may be a standalone component, or may be a component of a larger assembly (eg, the substrate may be an entire door panel or part thereof, etc.).

As shown in FIG. 1, a visual boundary (eg, seam or seam) is formed or provided between the skin 22 and the substrate 20, such that the substrate 20 forms a frame surrounding the skin 22. do. The size, shape, and configuration of the boundaries may vary in various exemplary embodiments. In addition, the boundary may be reduced in size or eliminated using at least partially filling material (eg, caulk, adhesive, liquid polymer, or other material) at the boundary. According to other embodiments, skin 22 and substrate 20 may be provided in this manner to minimize visual boundaries. Figure 5 shows one exemplary embodiment showing the bond between the skin and the substrate.

Any one of a variety of configurations can be utilized for the interface of the edge of the substrate and the skin. According to an exemplary embodiment, the flange 30 is formed above the skin 22 by forming a vacuum mold (ie, providing a "folded back" configuration at the edge of the skin to form a protrusion). The substrate 20 is formed around the flange 30 of the skin 22. According to a preferred embodiment, the skin 22 and the substrate 20 are joined together to provide a relatively hermetic and / or watertight seal. In one example, the skin includes a flange 30 that extends substantially entirely around the perimeter of the skin 22, and the substrate 20 is formed around the flange 30 (eg, the skin 22 is provided and Forming a channel or groove extending substantially entirely around the periphery of the region containing the flange 30. Various sizes, shapes, and configurations may be used for the openings or grooves, protrusions or flanges that couple skin 22 to substrate 20.

According to an exemplary embodiment, the door is shown having an integral bolster and arm rests. The present invention is a die-cut, compressible filling material 24, such as a die-cut closed cell foam that is attached (via a pressure sensitive adhesive or similar process) to a vac-form skin 22. To utilize. That portion is located in the tool and the plastic is molded around the assembly to form the substrate 20. Where the compressible filling material 24 (and skin 22) is present, there is a soft, compressible feel in that portion. Where there is no compressible filling material 24 behind the skin 22, there is a harder feel in that part. Using this innovative process, door trim panels can be made to have multiple colors or fabrics or soft parts.

It is also important that the configuration and arrangement of the elements of the vehicle trim panel as shown in the preferred and other exemplary embodiments are merely exemplary. Although only some embodiments of the present invention have been described in detail herein, those skilled in the art having reviewed this specification have provided many modifications (eg, without departing substantially from the novel teachings and advantages of the subject matter recited in the claims). It will be readily understood that various factors, variable values, mounting arrangements, variations in size, dimensions, structure, shape and proportions of material, color, orientation, etc. are possible. Accordingly, it will be appreciated that all such changes are included within the scope of the invention as defined in the appended claims. The order and sequence of any process or method steps may vary or rearrange according to other embodiments. In the claims, any functional claims may be understood to include the structures described herein, as well as structural equivalents and equivalent structures, to carry out the functions mentioned. Other substitutions, changes, variations, and / or omissions may be made in the design, operating conditions and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the invention as set forth in the appended claims.

Claims (22)

Forming a flexible skin 22 and forming a flange 30 extending substantially entirely around the periphery of the skin 22; Coupling the compressible material 24 to the skin 22, Positioning the skin 22 and the compressible material 24 in the mold, The compressible material (1) extends substantially entirely around the periphery of the area where the skin (22) is provided and provides a first boundary with a visual boundary (28) formed by grooves of the substrate (20) containing the flange (30). 24 and forming a rigid substrate 20 by molding surrounding the flange 30 of the skin 22, The compressible material (24) is disposed between the skin (22) and the substrate (20) such that the first soft zone is formed by the compressible material (24). The method of claim 1, wherein the flange (30) comprises a folded configuration forming a protrusion. The method of claim 1, wherein the substrate (20) comprises a molded polymeric material. The method of claim 3, wherein the skin (22) is formed by trimming and vacuum forming the sheet. The method of claim 4, wherein the sheet is a thermoplastic olefin. The method of claim 5, wherein the compressible material (24) is a foam material. The method of claim 6, wherein the foam material is a closed cell foam. The method of claim 6, wherein the foam is attached to the skin (22). The method of claim 6, wherein the substrate (20) is formed to at least partially surround the flange (30). The method of claim 1, wherein the panel is a vehicle door trim panel (10). The method of claim 1, wherein after the skin (22) is formed, the compressible material (24) is bonded to the skin (22), and then the substrate (20) is molded into the skin (22) and the foam. The method of claim 1, wherein the second soft zone is formed by a portion of the skin (22) in direct contact with the substrate (20). The method of claim 1, wherein forming the substrate (20) comprises injection molding a plastic material. A flexible skin 22 having a flange 30 extending substantially entirely around the periphery of the skin 22, A compressible material 24 bonded to the skin 22, A rigid substrate 20 having grooves defining an area, The flange 30 of the skin 22 is joined and fitted into the groove of the substrate 20, the groove of the substrate providing a visual boundary defined by the groove and substantially extending around the periphery of the area where the skin 22 is provided. Extend overall, The compressible material (24) is positioned between the skin (22) and the substrate (20) and is configured to provide a first soft zone. 15. The component as claimed in claim 14, wherein the flange (30) comprises a folded configuration forming a protrusion. The component of claim 15, wherein the substrate comprises a molded polymeric material. 17. The component as claimed in claim 16, wherein the skin (22) is a sheet of vacuum molded and trimmed thermoplastic olefin material. 18. The component according to claim 17, wherein the compressible material (24) is a foam material. The component of claim 18, wherein the foam material is a closed cell foam. The component of claim 18, wherein the foam is attached to a skin. 15. The component according to claim 14, wherein the component is a vehicle door trim panel. The component according to claim 14, wherein the second soft zone is formed by a portion of the skin (22) in direct contact with the substrate (20).

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