Abstract:
A trim system configured to be received by a vehicle door substrate is provided. Some embodiments of the trim system include a locator and a feature. The feature is moveable relative to the locator after the locator is assembled with the substrate. Some embodiments of the trim system include a first and second feature. The second feature is moveable relative to the first feature after the first feature is assembled with the substrate.

Description:
BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The invention generally relates to trim systems for vehicle doors. 
     SUMMARY 
     A trim system is configured to be assembled in an assembled position with a vehicle door panel substrate having a pluraity of feature receiving portions and a plurality of receiving locators. The system includes a plurality of feature locators. At least one of the plurality of feature locators is configured to locate the trim system relative to the substrate via one of the plurality of receiving locators. The system also includes a plurality of trim features each connected with at least one of the plurality of feature locators. One of the plurality of trim features is moveable, after the trim system is located relative to the one of the plurality of receiving locators in order to position another one of the plurality of feature locators relative to another one of the plurality of receiving locators. 
     A trim system is configured to be assembled in an assembled position with a vehicle door panel substrate having a plurality of receiving locators and a plurality of feature receiving portions. The system includes a feature locator configured to locate the trim system relative to the substrate via one of the plurality of receiving locators. The system also includes a pair of trim features associated with the feature locator. Each of the pair of trim features is configured to be received by one of the plurality of feature receiving portions. The pair of trim features are hingedly moveable relative to each other in order to position the pair of trim features in the assembled position prior to locating the trim system relative to the substrate. 
     A trim system is configured to be assembled in an assembled position with a vehicle door panel substrate having a first feature receiving portion and a second feature receiving portion. The system includes a first trim feature configured to be received by the first feature receiving portion and a second trim feature configured to be received by the second feature receiving portion. The second trim feature is moveable, after the first trim feature is assembled with the substrate, relative to the first trim feature and within the second feature receiving portion to position the second trim feature within the second feature receiving portion in the assembled position. 
     While exemplary embodiments in accordance with the invention are illustrated and disclosed, such disclosure should not be construed to limit the claims. It is anticipated that various modifications and alternative designs may be made without departing from the scope of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1   a  shows a trim system in accordance with an embodiment of the invention; 
         FIG. 1   b  shows a front side of a substrate configured to receive the trim system of  FIG. 1   a;    
         FIG. 1   c  shows a back side of the substrate of  FIG. 1   b;    
         FIG. 2   a  shows a cross-section of a trim system in an as-molded position in accordance with an embodiment of the invention; 
         FIG. 2   b  shows a cross-section of the trim system of  FIG. 2   a  in an assembled position in accordance with an embodiment of the invention; 
         FIG. 3   a  shows a cross-section of a trim system in an as-molded position in accordance with an embodiment of the invention; 
         FIG. 3   b  shows a cross-section of the trim system of  FIG. 3   a  in an assembled position in accordance with an embodiment of the invention; 
         FIG. 4   a  shows a portion of a trim system in accordance with an embodiment of the present invention; 
         FIGS. 4   b  and  4   c  show the trim system of  FIG. 4   a  in further detail; 
         FIG. 4   d  shows a cross-section of the trim system of  FIG. 4   a  in accordance with an embodiment of the present invention; 
         FIG. 5   a  shows a portion of a trim system in accordance with an embodiment of the present invention; 
         FIG. 5   b  shows a cross-section of the trim system of  FIG. 5   a  in an as-molded position in accordance with an embodiment of the present invention; 
         FIG. 5   c  shows a cross-section of the trim system of  FIG. 5   a  in an assembled position in accordance with an embodiment of the present invention; 
         FIG. 6   a  shows a trim system in an as-molded position in accordance with an embodiment of the invention; 
         FIG. 6   b  shows the trim system of  FIG. 6   a  in an assembled position in accordance with an embodiment of the invention; 
         FIG. 7   a  shows a portion of a trim system in accordance with an embodiment of the present invention; and 
         FIG. 7   b  shows a portion of a trim system in accordance with an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
       FIGS. 1   a ,  1   b , and  1   c  show trim system  10 , e.g., cartridge, that may be assembled with vehicle door panel substrate  28 . Trim system  10  includes upper bolster  12 , arm rest  14 , lower bolster  16 , and side impact molding  18 . Trim system  10  also includes map pocket close-out  20 , speaker grill  22 , two-way slots  24 , and four-way round holes  26 . Two-way slots  24  and four-way round holes  26  are used to locate portions of trim system  10  to substrate  28  as will be explained in detail below. 
       FIG. 1   b  shows the front side of substrate  28 . Substrate  28  includes upper bolster opening  30 , arm rest opening  32 , and lower bolster opening  34 . Substrate  28  also includes an area  36  supported by side impact molding  18 , map pocket close-out opening  38 , and speaker grill opening  40 . Once assembled, portions of upper bolster  12 , arm rest  14 , lower bolster  16 , speaker grille  22 , and map pocket close-out  20  are visible through openings  30 ,  32 ,  34 ,  40 , and  38  or feature receiving portions, respectively. 
       FIG. 1   c  shows the back side of substrate  28 . Substrate  28  includes receiving locators  42 , e.g., heat stakes, that, in combination with feature locators, e.g., two-way slots  24  and four-way round holes  26 , locate trim system  10  relative to substrate  28 . 
     When molding trim system  10 , manufacturing tolerances may cause two-way slots  24  and four-way round holes  26  associated with each of upper bolster  12 , arm rest  14 , lower bolster  16 , side impact molding  18 , map pocket close-out  20 , and speaker grille  22  to be out of position relative to respective heat stakes  42  associated with openings  30 ,  32 ,  34 , area  36 , and openings  38 ,  40 . As a result, upper bolster  12 , arm rest  14 , lower bolster  16 , side impact molding  18 , map pocket close-out  20 , and speaker grille  22  are adjustable relative to each other as will be explained in detail below. 
       FIG. 2   a  a shows a cross-section of trim system  10  taken along section line  2   a - 2   a  of  FIG. 1   a . In the embodiment of  FIG. 2   a , these features are molded in different materials. As such, a knit line may occur in the connector, or tie, between these features. These features, however, may be molded in the same material. 
     Upper bolster  12 , arm rest  14 , and side impact molding  18  are shown in the as-molded position  44 . In the as-molded position  44 , axis  46  passes through each of upper bolster  12 , arm rest  14 , and side impact molding  18  as shown. 
       FIG. 2   b  shows upper bolster  12 , arm rest  14 , and side impact molding  18  in assembled position  48 . Arm rest  14  has been rotated relative to upper bolster  12  and now rests at approximately a 90° angle from axis  46 . Side impact molding  18  has translated relative to its molded position  44 . Connectors between upper bolster  12 , arm rest  14 , and side impact molding  18  allow for such movement as will be explained in detail below. 
       FIG. 3   a  shows a cross-section of an alternative trim system  10 ′ including upper bolster  12 ′, arm rest  14 ′, and side impact molding  18 ′ in molded position  44 ′. 
       FIG. 3   b  shows upper bolster  12 ′, arm rest  14 ′, and side impact molding  18 ′ in another assembled position  48 ′. In this assembled position, side impact molding  18 ′ and arm rest  14 ′ are rotated relative to upper bolster  12 ′. Again, flexible connectors between upper bolster  12 ′, arm rest  14 ′, and side impact molding  18 ′ allow for such movement as will be explained in detail below. 
       FIG. 4   a  shows the joint between upper bolster  12  and arm rest  14 . Upper bolster  12  includes upper bolster brim  50 , heat stake holes  52 , and kitting pin holes  54 . Substrate  28  further includes heat stakes (not shown) corresponding to holes  52  to facilitate attachment between trim system  10  and substrate  28 . Arm rest  14  includes kitting pins  56 . 
     Ribbon tie  58  connects upper bolster  12  with arm rest  14 . Ribbon tie  58  may be less than 1 mm thick, e.g., 0.5 mm. Ribbon tie  58  allows arm rest  14  to rotate relative to upper bolster  12  as shown in some of the previous Figures. Kitting pins  56  are snapped into kitting pin holes  54  thus holding arm rest  14  in place relative to upper bolster  12  as will be explained in detail below. 
       FIG. 4   b  shows a portion of arm rest  14 . Kitting pins  56  are molded perpendicular to die draw in the parting line of its tool. 
       FIG. 4   c  shows a kitting pin  56  in detail. Kitting pin  56  includes kitting pin flash  60 . Kitting pin flash  60  may be approximately 1 mm and, when inserted into a kitting pin hole  54 , may provide friction retention further holding arm rest  14  in place relative to upper bolster  12 . 
       FIG. 4   d  shows a cross-section of upper bolster  12  and arm rest  14  taken along section line  4   d - 4   d  of  FIG. 4   a . Upper bolster  12  and arm rest  14  are shown in an assembled position where a kitting pin  56  is inserted into a respective kitting pin hole  54  of upper bolster brim  50 . 
       FIG. 5   a  shows upper bolster  12 ′ and side impact molding  18 ′ in molded position  44 ′. Side impact molding  18 ′ includes side impact molding brim  62  and heat stake holes  52 . Ribbon tie  64  connects upper bolster  12 ′ to side impact molding  18 ′ and may be less than 1 mm thick, e.g., 0.5 mm. 
       FIG. 5   b  shows a cross-section of upper bolster  12 ′ and side impact molding  18 ′ taken along section line  5   b - 5   b  of  FIG. 5   a . Side impact molding  18 ′ and upper bolster  12 ′ include holes  52  capable of receiving corresponding heat stakes of substrate  28 . 
       FIG. 5   c  shows side impact molding  18 ′ in the as-kitted position, e.g., rotated 180° relative to upper bolster  12 ′. Side impact molding  18 ′ can be secured in place relative to upper bolster  12 ′ using heat stakes of substrate  28  inserted through holes  52 . 
     Referring to  FIGS. 1   a ,  1   b , and  1   c , lower bolster brim  68 , map pocket close-out brim  70 , speaker grille brim  72 , and variable length ties  74  are shown. Variable length ties  74  allow upper bolster  12 , lower bolster  16 , side impact molding  18 , map pocket close-out  20 , and speaker grille  22  to be positioned relative to one another as shown previously. 
     To assemble trim system  10  with substrate  28 , arm rest  14  would be rotated 90° relative to upper bolster  12  and secured in place via kitting pins  56  as explained with reference to  FIGS. 4   a - 4   d . Four-way round hole  26   a  would be inserted onto heat stake  42   a  and two-way slot  24   b  would be inserted onto heat stake  42   b . Manufacturing variability, however, may result in the rest of two-way slots  24  and four-way round holes  26  associated with lower bolster  16 , side impact molding  18 , map pocket close-out  20 , and speaker grille  22  to be misaligned relative to their respective heat stakes  42  of substrate  28 . 
     Variable length ties  74  allow lower bolster  16 , side impact molding  18 , map pocket close-out  20 , and speaker grille  22  to move relative to each other and relative to four-way round hole  26  and two-way slot  24  associated with upper bolster  12  such that the four-way round holes  26  and two-way slots  24  associated with each of lower bolster  16 , side impact molding  18 , map pocket close-out  20 , and speaker grille  22  may be aligned with their respective heat stakes  42  of substrate  28 . 
     With arm rest  14  rotated 90° relative to upper bolster  12  and secured in place as discussed above, lower bolster  16  can then be adjusted within opening  34  and placed onto appropriate heat stakes  42  followed by speaker grille  22 , map pocket close-out  20 , and side impact molding  18 . 
       FIG. 6   a  shows portions of trim system  10  in as-molded position  44 . “L” is the distance between four-way round hole  26   a  associated with upper bolster  12  and lower bolster  16 . “Q” is the distance between upper bolster  12  and lower bolster  16 . 
       FIG. 6   b  shows portions of trim system  10  after assembly with substrate  28 . Distance “L” in the as-molded position  44  is less than distance “L” after assembly with substrate  28 . Distance “Q” in the as-molded position  44  is less than distance “Q” after assembly with substrate  28 . 
       FIG. 7   a  shows a bellows configuration for a portion of tie  74 . This bellows configuration would allow features or locators connected with it to be adjustable.  FIG. 7   b  shows a curved configuration for a portion of tie  74 . This curved configuration would allow features or locators connected with it to be adjustable. Ties  74 , however, may have any suitable configuration, or be made from any suitable material, such as an elastomer, that would allow them to achieve a variable length. 
     System  10  may be molded using polypropylene (PP), acrylonitrile butadiene styrene (ABS), or any other suitable material. 
     Sequential valve gates may be used to fill each part separately. 
     To provide a full or partial coverstock, e.g., cloth or vinyl, Low Pressure Molding (LPIM) or In Mold Lamination (IML) techniques can be employed. These techniques allow a combination of covered and uncovered surfaces on a single part or sequence of parts. In either case the coverstock is hung in the tool and resin injected behind it. 
     Two shot molding technology can further enhance the surface finishes available within system  10 . In this case, either a moving core or rotating cavity technology can be employed. The two shot technique provides for areas of soft surface resins to be molded over a structural surface and thus provides well supported but soft regions. 
     Multi barrel technology can be used to inject multiple resins having, for example, differing structural, tactile, or color qualities to enhance the perception of quality in a vehicle. 
     In the event that features are molded from chemically incompatible materials that will not bond, these features may be mechanically attached either during the molding process in the tool or manually by the use of snaps at the demolding or kitting table. 
     While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.