i MANUFACTURE OF MULTIPLE INDOOR COMPONENTS OF MULTI-COLORED CARS SIZES AND TEXTURES
DESCRIPTION OF THE INVENTION: This invention relates generally to automotive clothing panels having multiple tire segments and to a method and apparatus for forming automotive clothing panels having multiple tire segments. It is known to thermoformed covers for composite plastic products such as foamed urethane parts covers are used to build interior trim panels of a vehicle. It is also known to form multiple or composite coverings made of two or more cover segments, then to join the composite cover to a rigid substrate to form a car cover panel. In the past, garment panels with composite coverings were made by layering coverage segments on a base covering. The composite cover would then be formed and attached to a rigid fiberglass or foam substrate in a separate passage. Such layering of the coverage segments is labor intensive and wastes the covering material in the aggregate layer cover. Another attempt to provide composite coverages is set forth in U.S. Pat. 4, 562, 025 granted on Dec. 31.
1985 to a common transferee. This patent presents multiple segments of coverage, formed by the emptying of dry thermoplastic material against a heated mold. A divider separates two different colors from the empty material as they are emptied against the heated mold from a powder box. A molten joint is then formed between the two castings or castings. Although suitable for its purpose, such a method requires that some of the empty material be wasted in the process. Furthermore, this process still requires that a separate step be made if the composite cover has to be joined to a rigid structure. It is also known to hand-coat and sew segments to form a garment cover portion. Although this method conserves the material it needs a lot of labor. It is also known to dielectrically bond the edges of multiple covers to form a cover of clothing part. There is minimal waste using this method but it requires a significant amount of work and is difficult and impractical to use in forming covers for contoured parts such as contoured door panels for the interior of a vehicle. When a garment panel includes more than one covering segment and the segments are made by joining two or more materials, for example, polyvinyl chloride (PVC) having different thicknesses or stiffnesses, it may be difficult to join the different materials to form a line of statically pleasing style or a seam between the segments. If, for example, one of two joined segments is cut from a thicker or stiffer material than the other, the thicker or stiffer segment will have a larger bending radius and will generally be more resistant to bending in a folded seam between two segments. Different bending radii can cause the seam to twist or curl unless steps are taken to permanently reinforce and stabilize the back seam. Similarly, if one cover segment is cut from a stiffer material than the other, it tends to unfold along the unfolded seam causing the other segment to bend, unless as previously described, the seam is permanently reinforced and stabilized from behind. A contracted seam can also provide a fine style line between the cover segments cut from materials with different colors and surface textures. An extremely fine style line between the segments can help to mask the fact that two different segments have been joined. A method and apparatus for producing a fine style line between the segments but reducing the waste of material and the needs of the work is established in the U.S. 4, 861, 543 granted on August 3, 1989 and granted to a common transferee. According to this method, the covering segments are joined together edge to edge forming a composite cover with slightly overlapping coarse seams. The composite cover is automatically heated and formed as a cloth in a thermoforming tool. The thermoforming tool automatically opens and applies a vacuum to unfold the rough seams inside the tool. Then the tool contracts the folded portions to form fine style lines terminated on the surface class A of the composite cover. The thermoforming tool has relatively movable mold parts that make up the composite cover and includes an expandable gasket configured to fold the coarse seams. The method and apparatus produces a thermoformed composite cover with finished style lines formed by tightening the folds on the hidden side of the composite cover. However, the cover is not attached to a rigid substrate or foam backing to form a complete panel of clothing in the same operation, then a second substrate is joined in another operation. Finally, the resulting substrates of the roof that are subassemblies are joined or mechanically fixed in a third operation. The above arrangements do not provide a dressing panel with a stabilized style line permanently supported and terminated between the cover segments of different thickness or stiffness. The above arrangements also do not provide a method or apparatus for joining two different cover segments and two rigid substrate components together to form a garment panel in a single operation. What is needed is an automotive clothing panel comprising two different cover segments attached to two rigid substrate components and joined together in a contracted seam to form a finished style line with permanent support where the two segments meet. of different cover. A method and apparatus that joins two different cover segments and two rigid substrate components together to form a single panel of clothing using less labor and fewer materials and without performing multiple operations is also needed. This invention provides an automotive clothing panel assembly that includes two different cover segments and two rigid substrate components joined together to form a single garment panel and in such a manner that it permanently supports a finished style line where two cover segments different ones are found, and a method and apparatus for manufacturing the garment panel assembly in a single operation. The garment panel assembly includes two different cover segments attached to two rigid substrate components and joined together in a contracted seam to form a continuous support for a finished style line where two different cover segments meet even when a segment has a grain noticeably heavier, a thickness or a support remarkably different. The two cover segments are joined together in a coarse seam that joins the cover segments into a single composite cover. Each substrate has a meeting flange that extends inward along a portion of each substrate perimeter. The composite cover includes a fold formed along the rough seam. The fold projects inward and remains sandwiched between the meeting flanges of the substrate forming a contracted joint that hides the rough seam. According to another aspect of the invention, a fixing element is arranged adjacent to the cover fold and the meeting flanges of the substrate. The fixing element joins the substrate meeting flanges together in that walls the cover fold between the meeting flanges and fixes the contracted joint. A garment panel made in accordance with the present invention is different from those shown in the prior art in that the rough seam between the segments of the cover is folded inwardly and is permanently sandwiched between the encounter flanges of the substrates. The flanges tighten the folded portion to produce a contracted seam and a fine style line. Because the flanges remain in that sandwich configuration they continue to support the seam after the finished garment panel is removed from the molded surfaces. In other words, the substrate meeting flanges maintain the appearance of the finished style line between the cover segments even when the cover segments have different textures, colors, compositions and thicknesses. According to this invention there is provided a method for forming a car skin panel by joining each of two segments to a one of two rigid substrate components and joining the resultant cover substrate subassemblies together along flanges of encounter substrate coupling so that the cover segments are along a finished joint line. The method includes joining the joining edges of the cover segments together to form a coarse seam, which supports the substrate components in moveable mold components with the substrate meeting flanges by engaging gripping surfaces of the mold components, locating the movable mold components in a spaced open position, applying vacuum or air formation and joining the cover segments to the upper surfaces of the substrate components with a portion of the joined segments covering the space between the components of the open mold with the Coarse stitching lying along the space approximately midway between the gripping surfaces of the mold components, apply pressure along the seam to fold the tensioned portion of the cover inwardly between the gripping surfaces mentioned in FIG. so much that the gripping surfaces move together to a position fastened The gripping surfaces of the mold component cause the substrate meeting flanges to sandwich the inwardly folded cover portion thereby forming a finished style line between the cover segments and concealing the rough seam. According to another aspect of this method, a vacuum is applied to the cover segments through the substrate components. The vacuum ensures an adequate bond between the cover segments and the substrate components. According to another aspect of this method, the substrate meeting flanges are fixed together against the folded cover portion with a fastener. The fastener fixes the meeting or coupling flanges of the substrate in the sandwich position on each side of the folded cover portion and serves to permanently grip and hold the contracted seam while maintaining the appearance of the ethyl line terminated between the cover segments. According to yet another aspect of this method, the cover segments are heated before the support stage 5 of the cover segments on the upper surfaces of the upper segments of the substrate components, that is, before the formation with Vacuum or air pressure of the cover segments. The method of the present invention is different from
those presented in the prior art because two cover segments two rigid substrates with flanges of
• Coupling come together to form a fine style line in a single operation. In addition, due to the inwardly folded portion of the merged cover, the segments remain
sandwiches between the flanges, there is no need to cut the rough seam or coat the folded material after forming the contracted seam. In accordance with this invention, an assembly of
• mold for. Ormar a car clothing panel from two
different cover segments and two different substrate components, each cover segment having a coupling or pre-joining edge to a meeting edge of the other cover segment to form a coarse seam and each substrate component is doubled as long of an edge
to form a coupling or coupling flange. The assembly includes movable mold components having respective gripping surfaces. The components of the mold have an open position to receive the substrate components. In the open position, the gripping surface is separated to receive and fit the flanges. The assembled cover segments are extended over the substrate components with the coarse seam extending along the portion of the joined cover segments covering the space between the gripping surfaces. The mold components also have a gripping position for gripping the tensioned portion of the cover segments assembled between the coupling or encounter flanges of the substrate. An auxiliary forming member is supported outwardly from and between the gripping surfaces of the mold component in the open position and is movable inward to provide inward pressure along the rough seam of the cover to cause the The tensioned cover portion is folded inward when the mold components move together towards the gripping or holding position. In accordance with another aspect of the invention, the mold components are adapted to allow a vacuum to be applied to the cover segments through the substrate components. Alternatively, the mold components can be adapted to allow the air pressure to be applied to the cover. Vacuum or positive air pressure causes the cover to mold against the substrate components. In accordance with another aspect of the present invention, the mold components are adapted to support a fastener for securing the flanges for meeting the substrate together between so that they sandwich the folded portion inwardly of the cover. The apparatus of the present invention is different from that presented in the prior art in that the mold assembly includes an auxiliary molding member that provides an inward pressure to assist in folding the rough seam between the cover segments when the two movable components of the mold are assembled. mold seals closer to a grip position to form the contracted seam. DESCRIPTION OF THE DRAWINGS To better understand and appreciate the invention, the following detailed description of the invention follows with reference to the drawings in which: Figure 1 is a fragmentary cross-sectional side view of a garment panel constructed in accordance with the present invention; Figure 2 is a fragmentary cross-sectional side view of two cover sections assembled before being assembled in the clothing panel of Figure 1;
Figure 3 is a fragmentary cross-sectional side view of two substrate components before assembly in the garment panel of Figure 1; Figure 3a is a fragmentary cross-sectional side view of a second embodiment of one of the substrate components of Figure 3; Figure 4 is a cross-sectional side view of the cover sections of Figure 2 and the substrate components of Figure 3 mounted on a pair of mold components during assembly in the clothing panel of Figure 1; and Figure 5 is a cross-sectional side view of the cover sections of Figure 2 and the substrate components of Figure 3 mounted on the mold components of Figure 4 after assembly in the clothing panel of the Figure 1. A car body panel assembly is shown at 10 in Figure 1. The assembly 10 includes a first segment of vinyl cover 12 having an outer surface of class A 14 and a hidden internal surface 16. An edge of coupling or encounter 18 is disposed along a portion of the perimeter of the cover link joining both the outer surface 14 and the internal surface 16. The assembly 10 also includes a second segment of vinyl cover 20 with an external surface 22 , an inner surface 24 and a meeting edge 26 disposed along a portion of a common perimeter joining the outer surface 22 and the inner surface 24. The second segment of c slot 20 is attached to the first cover segment 12 along the respective engagement or joining edges 18, 26 forming a coarse seam, indicated by the numeral 28 in Figures 1, 2, 4 and 5. The rough seam 28 the cover segments 12, 20 in a single composite cover and the external surfaces 12, 22 in a single composite external surface. A first rigid substrate component generally indicated at 30 in Figures 1 and 3-5 is attached to the first internal surface of cover 16. A second rigid component of substrate, indicated by the figure 32 in Figures 1 and 3-5, it is attached to the second internal surface 24. A coupling or engagement flange 34, 36 extends inward from each respective substrate component 30, 32 at a ninety degree angle from a peripheral edge of each substrate component 30, 32. The meeting flanges 34, - - 36 are arranged parallel to each other. As best seen in Figures 4 and 5, the composite cover 12, 20 includes a tensioned or bridged portion 38 that is folded inwardly along the rough seam 28 and projects inwardly between the parallel encounter flanges 34. , 36. As shown in Figure 5, the folded portion 38 is sandwiched between the meeting flanges 34, 36 to form a shrunk joint 40 on an outer composite cover surface 14, 22. The shrinkage joint 40 provides a finished line of precise style between the outer cover surfaces 14, 22 and conceals the rough seam 28. As shown in Figures 1, 4 and 5 an adhesive layer 42 is included between the first substrate component 30 and the first cover segment 12 and between the second substrate component 32 and the second cover segment 20. The adhesive layer 42 may include any or a combination of suitable adhesives as is known in the art. As shown in Figures 1 and 5 a fixing element 44 extends from one of the meeting flanges 36 and passes through the folded-inward portion of the cover 38 within a receiving hole 46 of the fixer in the other flange of the flange. meeting 34. The fixing element 44 joins the meeting or coupling flanges 34, 36 as long as they sandwich the folded cover portion inwardly 38 between them and permanently fix the contracted seal 40. Preferably the fixator 44 comprises an injection molded spindle. In Figures 1 and 5, the fastener 44 is a spindle having a base integrally connected to one of the substrate flanges 36, and a conical tip extending through the fastener receiving hole 46 and engaging the other substrate flange 34. As shown in Figure 3A, the fastener 44 * can alternatively comprise a spring fastener. The fixator can also be any other mechanically connected device known in the art, for example staples, rivets, clamp screws or injection molded spindles that are fitted by snapping or hot-nailing. In practice, the meeting edges 18, 26 of the cover segments 12, 20 are first joined to form the rough seam 28. Preferably the cover supplier accomplishes this and sends a pre-assembled composite cover 12, 20 for assembly by the manufacturer of the piece of clothing. The adhesive layer 42 is then applied to the external surfaces 60, 62 of the substrate components 30, 32. As shown in Figure 4 the first and second rigid substrate components are then mounted on the external forming surfaces 48, 50 of the movable mold components first 52 and second 54 with the mold components 52, .54 arranged in an * open "open" position. When the components of the substrates 30, 32 are mounted on the mold components 52, 54 the coupling flanges or substrate encounter 34, 36 couple the mold components 52, 54 extending downward and in line seating against the gripping surfaces of the mold component 56, 58. This prevents the substrate components 30, 32 from slipping out of the mold components 52, 54 and places the substrate components 30, 32 ready for subsequent operations. In other embodiments, the adhesive layer 42 can be applied to the outer surfaces of the substrate 60, 62 after placing the substrate components 30, 32 in the mold. The attached cover segments 12, 20 are then heated and spread on the outer surfaces of the adhesive coated substrate 60, 62. The cover segments 12, 20 are heated to allow said segments to conform to the shape of the surfaces outer of substrate 60, 62. The portion 38 of the cover segments 12, 20 covering the space between the open mold components 52, 54 is arranged so that the rough seam 28 lies along the space approximately in the center between the gripping surfaces of the mold component 56, 58. Inward pressure is applied to the extended cover portion 38 along the coarse seam 28 while the mold components 52, 54 are moved to an embraced position shown in Figure 5. Inward pressure 'folds the stretched cover portion 38 inwardly between the substrate component mounting flanges 34, 36. When the flanges 34, 36 move come together, the inward pressure is suspended and the substrate meeting flanges 34, 36 press against each other - sandwiching the folded cover portion 38. By sandwiching the folded cover portion 38 the two class A surfaces 14, 22 of the sections heated cover 12, 20 are forced to join causing them to melt. A finished style line is formed between the class A surfaces 14, 22 of the cover segments 12, 20, at the point where the two surfaces, class A, 14, 22 are fused together. The finished style line conceals the coarse seam 28. At the same time that the mold components 52, 54 are moving together, a vacuum is applied to the cover segments 12, 20 through the substrate components. , 32. The vacuum pulls the coupled cover segments 12, 20 inward against the substrate components 30, 32 improving the cover adhesion to the substrate components 30, 32. Alternatively, the positive air pressure can be applied to the surface of the cover segments 12, 20 forcing the cover segments 12, 20 to be configured with the substrate. In other embodiments, a combination of vacuum pressure and air pressure may be employed. With the mold components 52, 54 spaced apart, the fastener 44 is assembled or molded so that it protrudes from one of the meeting flanges 36 at an opposite point of the fastener receiving hole 46 in the opposite engagement flange 34. A half that the mold components 52, 54 move towards their engaged position, the fastener 44 is forced through the folded cover portion 38 into the fastener receiving hole 46 at the opposite flange 34. This secures the encounter flanges or coupling 34, 36 together in a position that walls the tensioned portion of the folded cover inwards 38 between them. Following molding, gripping and fixing the mold components 52, 54 are moved back to the open position and the substrate assembly 10 - complete cover is removed. An apparatus for practicing the method is represented in Figures 4 and 5 as including a thermoforming tool or a forming die that is operated to provide composite covers with a minimum waste of material, with shaped style lines and hidden seams. The thermoforming tool or forming die includes a mold assembly with an expandable gasket. The expandable gasket is defined by the movable mold components 52, 54 and the gripping surfaces 56, 58 as described. In its open position, the expandable joint is covered and the mold components 52, 54 are separated, the mold components 52, 54 are moved to the open position so that the substrate components 30, 32 can be mounted between the surfaces of open coupling 56, 58 of the mold components 52, 54. In other words with the mold components 52, 54 in the open position, the gripping surfaces 56, 58 are spaced apart allowing them to receive and engage the substrate meeting flanges 34, 36 while the joined cover segments 12, 20 are attached to the outer surfaces of the substrate components. In practice, the joined cover segments 12, 20 are put through and spread as fabric over the substrate components 30, 32 after the substrate components have been placed in the mold components 52, 54. The covers 12, 20 are placed on the mold components 52, 54 with the rough seam 28 extending along the previously described tensioned portion 38 of the joined cover segments 12, 20. The mold components 52, 54 are adapted for allowing a vacuum to be applied to the cover segments 12, 20 through the substrate components 30, 32. As described above, the air pressure differential, this is the application of vacuum pressure, positive air pressure or both, it helps to improve adhesion between the cover segments 12, 20 and the substrate segments 30, 32. As shown in FIGS. 4, an auxiliary mold member 64 is supported outwardly from and within e the gripping surfaces of the mold component 56, 58 when the mold assembly is in the open position. The auxiliary member 64 is movable inward to provide inward pressure along the coarse cover seam 28 when the mold components 52, 54 move together towards the gripping position. The auxiliary molding member 64 causes the tensioned cover portion 38 to fold inwardly when the mold components 54, 56 move together to the locked position, where as described, the attached cover segments 12, 20 are sandwiched and gripped between the substrate encounter flanges 34, 36. The mold components 52, 54 are adapted to accommodate a fastener 44 for securing the coupling flanges 34, 36 together while the encounter flanges 34, 36 are sandwiching the inwardly folded taut portion 38 of the composite cover 12, 20. To allow a fastener 44 that is mounted on or integrally extends from a substrate encounter flange 36, pass through and engage in the fastener receiving hole 46 in the other substrate meeting flange 34 a mold component gripping surface 56 is recessed in the tool. In other words, a gripping surface 56 includes a recessed recessed area 66 below the fixator receiving hole 46. The relief area prevents the gripping surface 56 from obstructing the passage of the fixator 44 through the fixator receiving hole 46. The composite cover 12, 20 can initially be supported on a frame for heating and transport to mold components 52, 54 for air pressure or vacuum molding as described in U.S. 4, 861, 543 granted to the assignee of the present invention and incorporated by reference. After assembly, the finished garment panel 10 can be unloaded from the mold by any of the methods known in the art, including the method described in U.S. 4, 861, 543 already mentioned. In producing garment panels according to the present invention allows the use of two different grains of cover in a piece of automotive clothing such as an instrument panel. For example using a method according to the invention, garment panel manufacturers can use heavier grain cover material, with different thickness, or backing on the top cover of an instrument panel to improve the reflective qualities and the weather resistance This invention also combines melted vinyl, adhesive and fasteners in such a way that the need for hot embedding is eliminated. In addition, it saves material in the area where two cover segments come together by eliminating the need to include 10 1 3 cm of additional cover material or "run off". The additional material is required when the first segment 12 and the substrate component are formed separately from the second cover segment 20 and the substrate component, which are then put together in a subsequent operation. This is a description of the invention that uses descriptive and non-limiting words. Obviously it is possible to modify and vary this invention in light of its teachings. Within the scope of the claims one may practice the invention in another way than as described. For example, various types of thermoforming can be used to include heat deforming contact, forming pressure and expanding air formation. The cover can be one of a polyvinyl chloride (PVC) material or it can be a broad molding range of deformable sheet or both natural and synthetic film materials. Instead of heating the vinyl cover material enough to seal the contracted joint, a suitable dielectric heater can be used to complete the seal on the contracted joint. Several other changes in the configuration of the apparatus, in the form of the product and methods could also be made to meet the design-objectives of adjustment and operation according to a particular cover, for a particular composite product.