Abstract:
A method for forming an integrated trim plate in a single processing step. An appliqué section is reversibly securing to the lower section of a mold. A layer of thermoplastic covering is applied onto and over the appliqué section and lower section of the mold. A layer of foam is then injected between the thermoplastic covering and a substrate used to secure the integrated trim plate within a structure such as an automobile frame. The appliqué section may be magnetically secured to the lower section of the mold or may be physically secured within a forming section of the lower section.

Description:
BACKGROUND OF INVENTION 
     The present invention relates generally to trim plates, and more particularly to an integrated trim plate with a thermoplastic cover. 
     A recent trend in the automobile industry has been the development of various non-fabric automotive trim components. Automotive interior trim articles such as instrument panels, door panels, armrests, headrests, floor consoles, knee bolsters, and glove compartment doors conventionally have been constructed by applying a soft decorative covering over a rigid substrate mountable in an automobile vehicular body, with a cellular polyurethane padding interposed between the decorative covering and rigid substrate. A predetermined texture and color is usually provided to the decorative covering in an effort to simulate the appearance and feel of authentic leather. 
     These decorative coverings suffer from a number of potential drawbacks. For example, current processes are both complex and time-intensive and can lead to increased manufacturing costs. Further, these components suffer from non-ideal fit and finish. 
     It is therefore an object of the present invention to provide an integrated trim plate that is capable of integrating many potential components. It is another object to provide a process for making trim plates having high craftsmanship, good fit and good finish in a single processing step. The trim plates may then be coupled within a wide variety of potential systems, including within an instrument panel and door trim. 
     SUMMARY OF INVENTION 
     In accordance with the above objects to provide a method for applying a spray thermoplastic cover over an appliqué section that is subsequently formed into an integrated trim plate by introducing a foamed section between the thermoplastic cover and the hard plastic or metal substrate. 
     In one aspect of the present invention, the appliqué section is placed within a formed section of a tool. The thermoplastic cover is sprayed over the appliqué section and tool to adhere the appliqué section to the cover. The formed section is designed to hold the appliqué section in place during the spraying process. 
     In another aspect of the present invention, the thermoplastic cover is applied to an appliqué section that is magnetically affixed to a tool. The entire tool may comprise the magnet, or portions of the tool may comprise the magnet. 
     Integrated trim plates formed according to the preferred embodiments described above are easily formed in one processing step, thereby decreasing manufacturing costs. In addition, the integrated trim parts offer good fit and finishes. 
     Other objects and advantages of the present invention will become apparent upon considering the following detailed description and appended claims, and upon reference to the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  is a section view of an integrated trim component according to one preferred embodiment of the present invention; 
         FIG. 2  is a section view of the process for forming the thermoplastic cover on the appliqué section of  FIG. 1  according to one preferred embodiment of the present invention; 
         FIG. 3  is a section view of the process for forming the thermoplastic cover on the appliqué section of  FIG. 1  according to another preferred embodiment of the present invention; 
         FIG. 4  is a section view of the process for forming the thermoplastic cover on the appliqué section of  FIG. 1  according to another preferred embodiment of the present invention preferred embodiment of the present invention; and 
         FIG. 5  is a section view of the process for forming the interior trim component of from  FIGS. 1–4 . 
     
    
    
     DETAILED DESCRIPTION 
     Referring now to the drawing,  FIG. 1  illustrates a typical article that can be made in accordance with the present invention in the form of an interior trim component  10 , or integrated trim component, for an automobile. The trim component comprises an outer thermoplastic cover  12 , a substrate  14  sometimes referred to as an insert, and a shaped foam cushion  16  between the cover  12  and substrate  14 . A simulated leather appliqué section  18  is also coupled within a portion of the outer thermoplastic cover  12 . 
     The thermoplastic cover  12  can be made of any suitable thermoplastic material that is aesthetically pleasing and feels good to the touch. Preferably, the thermoplastic cover is a thin skin of polyurethane. However, other possible thermoplastic cover  12  materials include but are not limited to thermoplastic polyolefins (TPO), thermoplastic elastomers, polyvinylchloride (PVC) and polyesters (PE). 
     The substrate material  14  can be made of a material that is of sufficient strength for handling or fastening the component  10  to a support structure such as an automobile frame or door. The material must also be compatible with the material of the cover  12  and of the foam cushion  16 . The substrate material  14  is typically made of metal or plastic. Typical examples of metal include steel, aluminum, magnesium, as well as various alloys well known in the art. Typical examples of plastic include but are not limited to structural thermoplastic materials such as polycarbonate, acrylonitrile-butadiene-styrene (ABS), or thermoplastic polyolefins (TPO). 
     The foam structure  16  is well known to those of skill in the art to provide a soft feel to the trim component  10  and fill out the trim component  10  while contributing little in terms of overall cost and weight. The foam is preferably semi-rigid when completely reacted. Typically, the foam structure  16  is constructed of polyurethane foams. However, other foams may be used as well, including but not limited to polyurea-formaldehyde foams, polyether foams, and polyisocyanurate foams. One preferred foaming structure  16  utilized in the present invention is 21635R, a polyurethane foam commercially available from BASF. 
       FIGS. 2–4  illustrates a sectional view three preferred processes for sealing the thermoplastic cover  12  to the appliqué section  18  to form a thermoplastic sealed appliqué section  42 . 
     Referring now to  FIG. 2 , the process for forming the thermoplastic sealed appliqué section  42  begins by first coupling the appliqué section  18  within a corresponding formed section  22  within a tool  20 . As shown below in  FIG. 5 , the tool  20  is the bottom portion of the mold  56  used to form the integrated trim plate  10 . The tool  20  is preferably the lower section of a mold, and thus tool  20  and lower section  20  are used interchangeably herein. 
     The formed section  22  is shaped to correspond to the outer finished surface  19  of the appliqu é section  18 . The formed section  22  is also designed to hold the appliqué section  18  firmly to the tool  20  during subsequent application of the thermoplastic cover  12 . 
     Alternatively, as shown in  FIG. 3 , the appliqué section  18  is metallic and is coupled to the tool  20  that has the opposite magnetism of the appliqué section  18 . The tool  20  itself therefore must be formed of a magnetic material. Preferably, the tool  20  is formed of nickel. Thus, the appliqué section  18  sticks to the tool  20  without the need for a special formed section as in  FIG. 2 . In this way, the tool  20  does not have to be manufactured with specially designed forming sections  22  that correspond to the shape of the appliqué section  18  desired for each vehicle&#39;s varying interior trim components. 
     In  FIG. 4 , a magnet  38  is coupled within a cutout portion  44  of the tool  20 , rather than the entire tool  20  being magnetized as in  FIG. 3 . The location, size, and shape of the magnet  38  can vary greatly depending upon numerous factors. These factors include but are not limited to the shape of the appliqué section  18 , the amount of magnetic adherence required between the appliqué section  18  and the magnet  38  to ensure that the appliqué section  18  is firmly held in place during subsequent steps, and manufacturing costs gleaned to couple the magnet  38  within a portion of the tool  20 . Thus, the magnet  38  could be contained within a cutout portion  44  as shown in  FIG. 3 , or could form a shell (not shown) around the entire tool  20 . 
     In all of the embodiments described above in  FIGS. 2–4 , a liquid resin  24  is subsequently sprayed through a fluid nozzle  26  onto the surface  25  of the tool  20  and onto the backside  28  of the appliqué section  18  to a uniform thickness. The liquid resin  24  crosslinks or otherwise reacts to form the outer thermoplastic cover  12  that is substantially sealed to the appliqué section  18 , therein forming a thermoplastic sealed appliqué section  42 . The thickness of the outer thermoplastic cover  12  is between 0.5 and 2.0 mils, and more preferably between 0.8 and 1.2 mils. 
     Preferably, the liquid resin  24  is a two-component polyurethane material formed by crosslinking an aromatic or aliphatic polyol material and an isocyanate crosslinker material. One preferred two-component urethane is Elastolit MS0690R, manufactured by BASF Corporation. 
     To aid in sealing the thermoplastic cover  12  to the appliqué section  18 , one or more tabs  30  (best shown in  FIGS. 3 and 4 ) may be added to the appliqué section  18  along its exterior surface. The liquid resin  24  migrates around the tabs  30  during the spray application process. 
       FIG. 5  describes a preferred process for forming the integrated trim plate  10  from the thermoplastic sealed appliqué section  42  made in  FIGS. 2–4 . 
     As shown in  FIG. 5 , a coating of foam material  16  is sprayed or otherwise applied onto substantially the entire back surface  52  of the thermoplastic cover  12  in a substantially uniform manner. The mold  56  is closed such that the upper portion  58  of the mold is sealed to the tool  20  and such that the substrate  14  is located within the mold cavity in spaced relationship to the thermoplastic cover  12 . The closed mold  56  is clamped shut as indicated by force arrows  60  while the foam material  16  reacts to fill the mold cavity between the cover  12  and the substrate  14 . The foam material  16  is preferably a semi-rigid type when the chemical reaction is complete. The mold  56  is opened and the integrated trim plate  10  is removed. 
     The integrated trim plates  10  formed in the present invention may be utilized in a wide variety of applications. Ideally, these trim plates are used as instrument panels, door panels, armrests, headrests, floor consoles, knee bolsters, and glove compartment doors. 
     The trim plates  10  formed according to the present invention offer many advantages over the prior art. For example, the present invention allows integration of various components, which decreased costs. Also, the present invention is easily manufactured with high craftsmanship. The appliqué section  18  is integrated into the thermoplastic cover with a good fit and finish. 
     While the invention has been described in terms of preferred embodiments, it will be understood, of course, that the invention is not limited thereto since modifications may be made by those skilled in the art, particularly in light of the foregoing teachings.