Abstract:
A method of manufacturing a vehicle trim panel having a storage compartment includes providing a first mold assembly comprising a first mold section and a second mold section, wherein the first mold assembly defines a first cavity. A second mold assembly is provided and comprises a third mold section and a fourth mold section. The second mold assembly defines a second cavity. A first material is introduced into the first cavity, thereby producing a substrate. A second material is introduced into the second cavity, such that the second material defines a cover member. The substrate and the cover member define a vehicle trim panel, such that the cover member defines an expandable portion of the storage compartment.

Description:
TECHNICAL FIELD  
       [0001]     This invention relates to interior vehicle components. More particularly, the invention relates to a method of manufacturing a vehicle trim panel having an integrated bezel.  
       BACKGROUND OF THE INVENTION  
       [0002]     It is known to provide an interior trim panel for a vehicle, and components thereof, which is aesthetically and/or tactilely pleasing to the vehicle occupants. Such trim panels may have a bezel disposed therein to allow for the placement of various door latch and switch assemblies within the trim panel.  
         [0003]     Known bezels are typically formed separately from the trim panel and assembled to the trim panel during an assembly operation subsequent to forming the trim panel. Such assembly operations can be complex and time consuming. It would therefore be desirable to provide an improved method of manufacturing a bezel formed in an interior vehicle trim panel.  
       SUMMARY OF THE INVENTION  
       [0004]     This invention relates to an improved method of manufacturing a vehicle trim panel having a integrated bezel for a door latch or switch assembly. The method includes providing a first mold assembly comprising a first mold section and a second mold section, wherein the first mold assembly defines a first cavity. A second mold assembly is provided and comprises a third mold section and a fourth mold section. The second mold assembly defines a second cavity. A first material is introduced into the first cavity, thereby producing a substrate and bezel. A second material is introduced into the second cavity, such that the second material defines a cover member. The substrate and the cover member define a vehicle trim panel having an integrated bezel.  
         [0005]     Various objects and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiment, when read in light of the accompanying drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0006]      FIG. 1  is a plan view of a vehicle trim panel manufactured in accordance with the method of the invention.  
         [0007]      FIG. 2  is a cross sectional view of the vehicle trim panel taken along line  2 - 2  of  FIG. 1 .  
         [0008]      FIG. 3  is a cross sectional view of the vehicle trim panel taken along line  3 - 3  of  FIG. 1 .  
         [0009]      FIG. 4  is a schematic cross sectional view showing the substrate illustrated in  FIG. 1  in a first mold assembly used in accordance with the method of the invention.  
         [0010]      FIG. 5  is a schematic cross sectional view showing the cover member and the substrate illustrated in  FIG. 1  in a second mold assembly used in accordance with the method of the invention.  
         [0011]      FIG. 6  is a perspective view showing the switch assembly and the vehicle trim panel of  FIG. 1  in accordance with the method of the invention.  
         [0012]      FIG. 7  is a cross sectional view of a first alternate embodiment of a vehicle trim panel manufactured in accordance with the method of the invention.  
         [0013]      FIG. 8  is a cross sectional view of a second alternate embodiment of a vehicle trim panel manufactured in accordance with the method of the invention.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0014]     Referring now to the drawings, there is illustrated in  FIGS. 1 through 3 , inclusive, a vehicle trim panel, generally shown at  10 . In the exemplary embodiment illustrated, the trim panel  10  is an automotive door trim panel or bolster which mounts to a vehicle door assembly  11 . It will be appreciated however, that the trim panel  10  of the subject invention may be any desired vehicle trim panel, such as a center console, an instrument panel, a cup holder, and the like. The illustrated trim panel  10  and vehicle door assembly  11  are, in large measure, conventional in the art and is intended merely to illustrate one environment in which this invention may be used. Thus, the scope of this invention is not intended to be limited for use with the specific structure for the trim panel  10  and vehicle door assembly  11  illustrated in  FIGS. 1 through 3 . On the contrary, as will become apparent below, this invention may be used in any desired environment for the purposes described below.  
         [0015]     The door panel  10  includes a substrate  12 . The substrate  12  includes an outer surface  14  and an inner surface  16 . The outer surface  14  of the substrate  12  faces the interior of the vehicle (not shown) when the door panel  10  is mounted to the vehicle door assembly  11 . The outer surface  14  may include at least one bezel  18  formed therein. As illustrated, the at least one bezel  18  includes a switch bezel  18   a  and a door latch bezel  18   b , although such is not required. The inner surface  16  may include at least one mounting apparatus or stake  20  extending therefrom to facilitate mounting the door panel  10  to the vehicle door assembly  11 . The substrate  12  may further define a flange  22 . In a preferred embodiment, the flange  22  includes an armrest portion  24  and a bezel portion  26 . As illustrated, the bezel portion  26  includes the switch bezel  18   a . In a preferred embodiment, the bezel portion  26  may include a support portion  26   a  and at least one mounting tab  26   b  to facilitate the mounting of a switch assembly  25  or other structure within the bezel portion  26 . It will also be appreciated that the door latch bezel  18   b  may include various tabs or apertures (not shown) to facilitate the mounting of a door latch assembly  26  within the door latch bezel  18   b.    
         [0016]     In a preferred embodiment, the armrest portion  24  and the bezel portion  26  may be formed such that an upper portion  24   a  of the armrest portion  24  and an upper portion  26   c  of the bezel portion  26  slope downwardly from the door panel  10  as the flange  22  extends outwardly from the door panel  10 . A cover member  28  is attached to the substrate  12 . Preferably, the cover member  28  is integrally molded to the substrate  12  according to the method of the invention, as will be described herein below. Preferably, the cover member  28  covers at least a portion of the outer surface  14  of the substrate  12 . In a preferred embodiment, the cover member  28  extends over the outer surface  14  of the substrate  12 , such that the armrest portion  24  of the flange  22  is covered by the cover member  28  and the switch bezel  18   a  and the door latch bezel  18   b  are exposed or not covered by the cover member  28 . Thus, the switch bezel  18   a  and the door latch bezel  18   b  are visible from the interior of the vehicle (not shown). A groove  29  may be formed in the substrate  12  to surround each of the at least one bezel  18  to facilitate the formation of the cover member  28  surrounding each of the at least one bezel  18 , as will be described below.  
         [0017]     In the exemplary embodiment illustrated, the substrate  12  includes a switch bezel  18   a  and a door latch bezel  18   b . It will be understood however, that the door panel  10  may include any number of bezels, including a single bezel, and that the at least one bezel  18  can have any desired shape, such as, for example, a substantially rectangular shape or substantially oval shape, and may have any desired number of openings or structures to accommodate the desired contents of the bezel.  
         [0018]     Referring now to  FIGS. 4 and 5 , there is illustrated a first mold assembly  30  and a second mold assembly  32 , respectively, which are adapted to be used in accordance with the method of this invention. Preferably, the first mold assembly  30  includes a first mold section  34  and a second mold section  36 , as shown in  FIG. 4 . The second mold assembly  30  includes a third mold section  38  and a fourth mold section  40 , as shown in  FIG. 5 . Preferably, the first mold section  34  functions as the third mold section  38 , as will be described herein. The first mold section  34  includes a first mold surface  42 , the second mold section  36  includes a second mold surface  44 , the third mold section  38  includes a third mold surface  46 , and the fourth mold section  40  includes a fourth mold surface  48 .  
         [0019]     Although illustrated schematically in  FIGS. 4 and 5 , it will be appreciated that the mold surfaces  42 ,  44 ,  46 , and  48  may be of any desired shape and contour. The mold sections  34 ,  36 ,  38 , and  40  are preferably mounted to platens (not shown) of a press (not shown), such as a vertical molding press with sufficient tonnage to accomplish the method herein described.  
         [0020]     The method of the invention will now be described. It will be appreciated, that in accordance with each embodiment of the invention as will be described below, a first step of the method of the invention includes providing a suitable mold assembly or assemblies, such as the mold assemblies  30  and  32 , respectively illustrated in  FIGS. 4 and 5 .  
         [0021]     A second step of the method of this invention is illustrated generally in  FIG. 4 . In the second step, the first mold assembly  30  is moved to a first closed position, as viewed in  FIG. 4 . In the first closed position, the first mold surface  42  of the first mold section  34  and the second mold surface  44  of the second mold section  36  define a first cavity  50 . As is known in the art, the mold assembly could include movable mold portions, such as a side slide or lifter indicated schematically at  52 , for creating the at least one mounting tab  26   b  while permitting the removal of the substrate  12  from the first mold section  34 . The lifter  52  may be positioned as desired to form the at least one mounting tab  26   b . A first material  54  is then introduced into the first cavity  50 . Any desired material can be introduced into the first cavity  50  in any manner. Preferably the first material  54  is molten plastic, such as polypropylene or glass-filled polypropylene. In a preferred embodiment, the first material  54  is a high-crystalline polypropylene (HCPP). It will be understood that any other desired thermoplastic can be used. The first material  54  then conforms to the shape of the first cavity  50 , thereby forming the substrate  12 . Preferably, the second mold section  36  is then moved away from the first mold section  36  in a direction D and the substrate  12  remains on the first mold section  34 , although such is not required. It will be appreciated that the first mold section  34  may also be moved away from the substrate  12  in a direction opposite the direction D, and to facilitate such movement, the lifter  52  may be moved to allow the substrate  12  to separate from the first mold section  34 . As illustrated, the lifter  52  may pivot about a point P to allow the substrate  12  to be removed from the first mold section  34 , although such is not required. It will be appreciated that the slope of the upper portion  24   a  of the armrest portion  24  and the upper portion  26   c  of the bezel portion  26  allow the first mold section  34  and the second mold section  36  to move away from the substrate  12  to release the substrate  12  from the first mold assembly  30 . In a preferred embodiment, the slope of the upper portion  24   a  of the armrest portion  24  is approximately 7° less than the slope of the die draw direction D, although such is not required. In a preferred embodiment, the slope of the upper portion  26   c  of the bezel portion  26  is approximately 15° less than the slope of the die draw direction D, although such is not required.  
         [0022]     A third step of the method of this invention is illustrated generally in  FIG. 5 . In the third step, the third mold section  38  and the fourth mold section  40  are moved into contact with one another and into a second closed position, thereby enclosing the substrate  12 , and defining the second mold assembly  32 . Preferably however, the substrate  12  remains in the first mold section  34  and the first mold section  34  comprises the third mold section  40 , such that first mold section  34  and the fourth mold section  40  are moved into contact with one another and into the second closed position, thereby defining the second mold assembly  32 .  
         [0023]     In the second closed position, the outer surface  14  of the substrate  12 , the third mold surface  46  of the third mold section  38  and the fourth mold surface  28  of the fourth mold section  40  define a second cavity  56 . A second material  58  is then introduced into the second cavity  56 . Any desired material can be introduced into the second cavity. Preferably, the second material  56  is molten plastic. More preferably, the second material  56  is a flexible material, such as a thermoplastic elastomer (TPE), thermoplastic elastomer-ether-ester (TEEE), or ethylene propylene diene monomer (EPDM). It will be understood that any other desired materials, such as other elastomers and non-elastomers, can be used. The second material  58  then conforms to the shape of the second cavity  56 , thereby forming the cover member  22 .  
         [0024]     In a preferred embodiment, the groove  29  has been formed to surround each of the at least one bezel  18 . The groove  29  and the fourth mold section  40  cooperate to prevent the second material  58  from covering each of the at least one bezel  18 .  
         [0025]     Preferably, the cover member  28  becomes thermally bonded to the substrate  12  during the molding process to form the door panel  10 . However, it will be appreciated that the cover member  28  and the substrate  12  may be thermal bonded and/or chemical bonded to one another, although such is not required. For example, features, such as recesses and protrusions, can be provided on a mold surface, such as the second mold surface  44  of the second mold section  36  to form corresponding recesses and protrusions in the outer surface  14  of the substrate  12 . Such recesses and protrusion will provide a mechanical bond with the cover member  28  after the molten second material hardens to form the cover member  28 . Alternately, holes or recesses can be formed in the substrate  12 , such that the second material  58  fills the recesses. The second material  58  thereby becomes bonded to the substrate  12  when the second material  58  hardens within the recesses.  
         [0026]     The third mold section  38  and the fourth mold section  40  are then moved away from one another and the door panel  10  is removed from the second mold assembly  32 . It will be appreciated that the method of the invention can be performed with satisfactory results in a shuttle-mold wherein the second and fourth mold sections  36  and  40  move relative to a stationary first mold section  34 . The method of the invention can also be performed with satisfactory results in a shuttle-mold wherein the first mold section  34  moves relative to stationary second and fourth mold sections  36  and  40 , or wherein the all mold sections  34 ,  36 ,  38 , and  40  move relative to one another.  
         [0027]     Referring now to  FIG. 6 , the switch assembly  25  is installed within the switch bezel  18   a . In addition to the at least one mounting tab  26   b , various apertures or tabs  60  may be formed on or in the bezel portion  26   a  to facilitate the mounting of the switch assembly  25  to the bezel portion  26 . The apertures or tabs  60  may be formed by the lifter  52  in a manner similar to that described for the at least one tab  26   b  or by any other known molding method. The switch assembly  25  may include various apertures or tabs  62 , which cooperate with the at least one tab  26   b  and the apertures or tabs  60  to retain the switch assembly  25  within the switch bezel  18   a . The bezel portion  26  may also include an aperture  64  to accommodate a wire harness  66  of the switch assembly  25  when the switch assembly  25  is positioned within the switch bezel  18   a , although such is not required. Additionally, the upper portion  26   c  of the bezel portion  26  may include at least one aperture  68  formed therethrough to accommodate a respective one of at least one switch  70  extending from the switch assembly  25 . In a preferred embodiment, each of the at least one switch  70  may be mounted to the switch assembly  25  to have a spring-load on each of the at least one switch  70 , such that each of the at least one switch  70  is spring-loaded to extend outwardly from the switch assembly  25 .  
         [0028]     In a preferred embodiment, an upper surface  25   a  of the switch assembly  25  is sloped at an angle approximately equal to the slop of the upper portion  26   c  of the bezel portion  26 . The support portion  26   a  and the upper portion  26   c  of the bezel portion  26  form a loading bin  72 . When the switch assembly  25  is loaded from the inner surface  16  of the substrate  12  into the loading bin  72  of the bezel portion  26  in a direction approximately equal to the direction D relative to the substrate  12 , the at least one switch  70  may be depressed by the upper portion  26   c  of the bezel portion  26  as the switch assembly  25  enters the switch bezel  18   a . Preferably, once the switch assembly  25  is aligned within the switch bezel  18   a , each of the at least one switch  70  will align with a respective one of the at least one aperture  68  and each of the at least one switch  70  will be urged through the respective one of the at least one aperture  68  by at least one spring  71  biasing each of the at least one switch  70  outward from the switch assembly  25 . Thus, each of the at least one switch  70  snaps into each respective one of the at least one aperture  68 . The slope of the upper portion  26   c  of the bezel portion  26  allows the switch assembly  25  to enter the switch bezel  18   a  without interference between the at least one switch  70  and the bezel portion  26 .  
         [0029]     The door panel  10  may be attached to the vehicle door assembly  11  using the stakes  20 , if the stakes  20  were formed as part of the substrate  12 , or by any suitable attachment method.  
         [0030]     Referring now to  FIG. 7 , there is illustrated a second embodiment of a door panel  110 , in accordance with the present invention. The illustrated door panel  110  is, in large measure, conventional in the art and are intended merely to illustrate one environment in which this invention may be used. Thus, the scope of this invention is not intended to be limited for use with the specific structure for the door panel  110  illustrated in  FIG. 7  or with door panels in general. On the contrary, as will become apparent below, this invention may be used in any desired environment for the purposes described below. The door panel  110  may be any interior vehicle component, such as an instrument panel, door panel, center console, seat assembly, armrest, visor, and other various interior panels for covering the sides, ceilings, vertical pillars of the frame members of the vehicle or any other component located within the interior of a vehicle.  
         [0031]     The door panel  110  is similar to the door panel  10  and generally only the components that differ will be described herein. Many of the components of the first embodiment of the door panel  10  as illustrated in  FIGS. 1 through 6  are similar in structure and function to corresponding components of the second embodiment of the door panel  110  as illustrated in  FIG. 7 . Therefore, such corresponding components are indicated by similar reference number in these Figures, but with the components of the second embodiment of the door panel  110  having the addition of 100 to each reference number.  
         [0032]     The door panel  110  is made in accordance with a second embodiment of the method of the invention. According to the second embodiment of the method, the substrate  112  is formed so that the substrate  112  comprises at least a portion of the vehicle door assembly. The substrate  112  may be mounted to the vehicle or another portion of the vehicle door assembly (not shown). In a preferred embodiment, a cover member  128  is formed so that the cover member  128  extends over an outer surface  114  of the substrate  112 , such that a switch bezel  118   a  and an outer portion  180  surrounding the cover member  128  are exposed or not covered by the cover member  128 . Thus, the switch bezel  118   a  and the outer portion  180  of the substrate  112  are visible from the interior of a vehicle when the door panel  110  is mounted to the vehicle.  
         [0033]     Preferably, the door panels  10  and  110  are manufactured using a two-shot molding process. The two-shot molding process may be accomplished by rotating the first mold section  34 , such as in a rotational molding process. In such a rotational molding process, the substrate  12  or  112  is first injection molded in the first mold assembly  30  as described herein. The first mold section  34 , containing the substrate  12  or  112  is then rotated to a second position wherein the first mold section  34  is joined with the fourth mold section  40  to define the second mold assembly  32  and the second cavity  56 . The cover member  28  is then injection molded in the second cavity  56 . Alternately, two separate molds could be used sequentially to form the substrate  12  and the cover member  28 .  
         [0034]     Referring now to  FIG. 8 , there is illustrated a third embodiment of a door panel  210  attached to a vehicle door assembly  211 , in accordance with the present invention. The illustrated door panel  210  and vehicle door assembly  211  are, in large measure, conventional in the art and are intended merely to illustrate one environment in which this invention may be used. Thus, the scope of this invention is not intended to be limited for use with the specific structure for the door panel  210  and vehicle door assembly  211  illustrated in  FIG. 8  or with interior vehicle components in general. On the contrary, as will become apparent below, this invention may be used in any desired environment for the purposes described below. The door panel  210  may be any interior vehicle component, such as an instrument panel, door panel, center console, seat assembly, armrest, visor, and other various interior panels for covering the sides, ceilings, vertical pillars of the frame members of the vehicle or any other component located within the interior of a vehicle.  
         [0035]     The door panel  210  is similar to the door panel  10  and generally only the components that differ will be described herein. Many of the components of the first embodiment of the door panel  10  as illustrated in  FIGS. 1 through 6  are similar in structure and function to corresponding components of the third embodiment of the door panel  210  as illustrated in  FIG. 8 . Therefore, such corresponding components are indicated by similar reference number in these Figures, but with the components of the third embodiment of the door panel  110  having the addition of 200 to each reference number.  
         [0036]     At least a portion of the vehicle door assembly  211  is formed in accordance with the method of this invention, as described for the substrate  12 . A substrate  212  may then be formed, such that the substrate  212  is thermally and/or chemically bonded to the vehicle door assembly  211 . A cover member  228  is then formed on the substrate  212  in a manner similar to that described for the formation of the cover member  28 . Preferably, the door panel  210  and vehicle door assembly  211  are manufactured using a three-shot molding process. The three-shot molding process may be accomplished by rotating a first mold section, such as in a rotational molding process. In such a rotational molding process, at least a portion of the vehicle door assembly is first injection molded in a first mold assembly. The first mold section, containing the door assembly  211  is then rotated to a second position wherein the first mold section is joined with a fourth mold section to define a second mold assembly and a second cavity. The substrate  212  is then injection molded in the second cavity. The first mold section, containing the door assembly  211  and substrate  212  is then rotated to a second position wherein the first mold section is joined with the fifth mold section to define a third mold assembly and a third cavity. The cover member  228  is then injection molded in the third cavity. Alternately, three separate molds could be used sequentially to form the door assembly  211 , the substrate  212  and the cover member  28 . It will be appreciated that the portion of the door assembly  211  to be thermally and/or chemically bonded to the substrate  212  may be formed by any process and then disposed within a mold cavity such that the substrate  212  is formed on the door assembly  211  in accordance with the invention.  
         [0037]     It will be further appreciated that the method of forming the door panels  10 ,  110 , and  210  of the invention can be satisfactorily performed wherein the cover member  28  is formed prior to the substrate  12 .  
         [0038]     The method of forming a vehicle door panel  10 ,  110 , or  210  having an integrated bezel  18 ,  118 , or  218  as described herein, is advantageous over prior art designs. The method of forming a vehicle door panel  10 ,  110 , and  210  is advantageous because the two-shot molding process eliminates the manual assembly of a cover member to a door panel required by the prior art methods. The method of the invention further improves quality, and eliminates the multiple components, such as support frames, fasteners, adhesives, and the like, of known vehicle trim panels.  
         [0039]     The principle and mode of operation of this invention have been described in its preferred embodiments. However, it should be noted that this invention may be practiced otherwise than as specifically illustrated and described without departing from its scope.