Abstract:
A method of manufacturing two trim components with a common mold assembly includes providing a mold assembly having a first cavity, a second cavity, and a movable mold element. The movable mold element is movable between a first position to expose the second cavity, and a second position to obstruct the second cavity. One of the two trim components is then produced. A first trim component is produced by positioning the mold element into the first position and then introducing a first material into the first and second cavities. A second trim component is produced subsequent to the mold assembly being provided. Then, the mold element is positioned into the second position. One of the first material and a second material is then introduced into the first cavity. The mold element is then moved into the first position, and a third material is introduced into the second cavity.

Description:
TECHNICAL FIELD  
         [0001]    This invention relates to interior vehicle trim panels. More particularly, the invention relates to a method of manufacturing interior vehicle trim panels.  
         BACKGROUND OF THE INVENTION  
         [0002]    It is known to provide an interior trim panel for a vehicle which is aesthetically and/or tactilely pleasing to the vehicle occupants. However, known methods of manufacturing interior vehicle trim panels may add significant cost to each vehicle produced. It would therefore be desirable to provide an improved method of manufacturing an interior trim panel for a vehicle.  
         SUMMARY OF THE INVENTION  
         [0003]    This invention relates to an improved method of manufacturing a first trim component and a second trim component with a common mold assembly. Initially, a mold assembly is provided. The mold assembly includes a first cavity, a second cavity, and a movable mold element. The movable mold element is movable between a first position to expose the second cavity, and a second position to obstruct the second cavity. One of the first trim component and the second trim component is then produced. The first trim component is produced by subsequently positioning the mold element into the first position. A first material then is introduced into the first cavity and the second cavity. The second trim component is produced subsequent to the mold assembly being provided. Then, the mold element is positioned into the second position. One of the first material and a second material is then introduced into the first cavity. The mold element is then moved into the first position. Then, a third material is introduced into the second cavity.  
           [0004]    In another embodiment of the invention, the second trim component is produced subsequent to the mold assembly being provided. Then, a second material is introduced within one of the first cavity and the second cavity. The mold element is then positioned into the first position. Then, one of the first material and a third material is introduced into the first cavity, thereby substantially surrounding the second material with the one of the first material and the third material.  
           [0005]    In another embodiment of the invention, the second trim component is produced subsequent to the mold assembly being provided. Then, a second material is introduced within the first cavity. The mold element is then positioned into the second position. Then, one of the first material and a third material is introduced into the first cavity, thereby substantially surrounding the second material with the one of the first material and the third material. The mold element is then moved into the first position, and a fourth material is introduced into the second cavity.  
           [0006]    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  
       [0007]    [0007]FIG. 1 is an exploded perspective view of a vehicle trim panel manufactured according to the method of this invention.  
         [0008]    [0008]FIG. 2 is a cross sectional elevational view showing the vehicle trim panel illustrated in FIG. 1 in a mold used in accordance with a second step of the method of this invention.  
         [0009]    [0009]FIG. 3 is a reduced cross-sectional view of the vehicle trim panel and mold illustrated in FIG. 2, taken along line  3 - 3  of FIG. 2.  
         [0010]    [0010]FIG. 4 is a cross sectional elevational view of the mold illustrated in FIG. 2 showing a portion of a third step of the method of this invention.  
         [0011]    [0011]FIG. 5 is a cross sectional elevational view of the mold illustrated in FIG. 4 showing an additional portion of the third step of the method of this invention.  
         [0012]    [0012]FIG. 6 is a reduced cross-sectional view of the vehicle trim panel and mold illustrated in FIG. 5, taken along line  6 - 6  of FIG. 5.  
         [0013]    [0013]FIG. 7 is a cross sectional elevational view showing the vehicle trim panel illustrated in FIG. 1 in a mold used in accordance with a third step of an alternate embodiment of the method of this invention.  
         [0014]    [0014]FIG. 8 is a cross sectional elevational view of a vehicle trim panel showing the trim panel after the first step of the alternate embodiment of the method of this invention.  
         [0015]    [0015]FIG. 9 is a cross sectional elevational view of the vehicle trim panel illustrated in FIG. 7 showing the trim panel after the third step of the alternate embodiment of the method of this invention.  
         [0016]    [0016]FIG. 10 is a cross sectional elevational view showing the vehicle trim panel illustrated in FIG. 1 in mold used in accordance with a portion of a third step of an additional alternate embodiment of the method of this invention.  
         [0017]    [0017]FIG. 11 is a cross sectional elevational view showing the vehicle trim panel showing a additional portion of the third step of the alternate embodiment of the method illustrated in FIG. 10.  
         [0018]    [0018]FIG. 12 is a cross sectional elevational view showing the vehicle trim panel illustrated in FIG. 1 in a mold used in accordance with a third step of an additional alternate embodiment of the method of this invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0019]    Referring now to the drawings, there is illustrated in FIG. 1 a vehicle trim panel assembly, generally shown at  10 . The trim panel assembly  10  comprises a trim component or panel  12  of an electrically non-conductive material having an exterior surface  16 . Preferably, the trim panel includes an accent region  18 . The trim panel  16  of the preferred embodiment is an automotive door trim panel  12  which mounts to a vehicle door assembly, generally shown at  20 . It will be appreciated however, that the trim panel  12  of the subject invention may be any type of trim panel associated with a vehicle. For example, other types of trim panels include trunk panels, quarter panels, rear package trays, headliners, instrument panels, garnish moldings, and console panels, among others.  
         [0020]    The door trim panel  12  is preferably formed of a molded plastic material such as polypropylene. As appreciated by those skilled in the art, the trim panel  12  may be fabricated of other materials, such as wood fibers, polyurethane, solid molded vinyl, expanded polyurethane foam, any combination thereof, or any other suitable rigid, electrically non-conductive material. The exterior surface  16  of the trim panel  12  may include a decorative surface portion, such as accent region  18 , illustrated by a phantom line. The accent region  18  is also preferably formed of a molded plastic material such as thermoplastic urethane (TPU). As will be explained in detail below, the exterior surface  16  and the accent region  18  may be formed of the same or different materials. Further, as will be explained in detail below, the exterior surface  16  and the accent region  18  may have the same or different surface textures.  
         [0021]    Although not illustrated in FIG. 1, it will be appreciated that portions of the trim panel  12  may be covered with a decorative trim material such as cloth, vinyl, leather, and/or carpeting. The trim panel  12  may be attached to the vehicle door assembly  20  by suitable fasteners (not shown) as is well known in the art.  
         [0022]    Referring now to FIG. 2, there is illustrated a mold assembly, indicated generally at  24 , which is adapted to be used in accordance with the method of this invention. Typically, the mold assembly  24  includes a first mold half  26  and a second mold half  28 . The first mold half  26  includes a first mold surface  30 , and the second mold half  28  includes a second mold surface  32 . Although illustrated schematically in FIGS. 2 through 7, it will be appreciated that the mold surfaces  30  and  32  may be of any desired shape and contour. For example, first mold surface  30  might be a mold core, and second mold surface  32  might be a corresponding mold cavity. The first mold half  26  and second mold half  28  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. When in a closed position, as shown in FIG. 2, the first mold half  26  and the second mold half  28  form a first cavity  40 .  
         [0023]    The second mold half  28  includes a core cavity  34  for slidably receiving a movable mold element or core  36 . The movable core  36  can include a third mold surface  38 , and is movable between a first position, as shown in FIG. 2, and a second position, as shown in FIG. 4. When in the second position, the core  36  defines a second cavity  42 , shown in FIG. 2 in phantom line.  
         [0024]    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  24 ,  24 ′, and  102 .  
         [0025]    A second step of the method of this invention is illustrated generally at  22  in FIG. 2. In the second step  22 , the core  36  is moved upwardly, as viewed in FIG. 2, within the core cavity  34 , and into a first position. The first position is defined as a position wherein the third mold surface  38  of the core  36  defines a portion of the second mold surface  32 , thereby substantially exposing the second cavity  42 . A first material  46  is then introduced into the first cavity  40  and the second cavity  42  through a first passage  48 . Preferably the first material  46  is molten plastic, such as polypropylene. As shown in FIG. 3, both the first cavity  40  and the second cavity  42  are filled with the first material  46 . The first material  46  then conforms to the shape of the first cavity  40  and the second cavity  42 , shown in phantom line in FIG. 6, thereby forming the trim panel  12 . The trim panel  12  is then removed from the mold assembly  24  by any suitable method (not shown).  
         [0026]    A third step of the method of this invention is illustrated generally at  44  in FIGS. 4 and 5. In the third step  44 , the core  36  is moved downwardly within the core cavity  34 , as viewed in FIG. 4, and into a second position. The second position is defined as a position wherein the third mold surface  38  of the core  36  is positioned in a spaced relationship at a distance d from the first surface  30 . The core  36  thereby substantially obstructs the second cavity  42 . Preferably, the distance d is any desired distance greater than or equal to zero.  
         [0027]    A material is then introduced into the first cavity  40  through the first passage  48 . The material may be any suitable material, such as the first material  46 . Preferably the material is the first material  46 , and is molten plastic, such as polypropylene, although the first material  46  is not required. The core  36  is then is moved upwardly within the core cavity  34 , as viewed in FIG. 5, and into the first position, thereby exposing the second cavity  42 . A second material  50  is then introduced into the second cavity  42  through a second passage  52 , as shown in FIG. 6. The second material  50  may be molten plastic, such as polypropylene. Preferably, however, the second material  50  has characteristics different from the first material  46 , thereby creating an accent region  18  having an aesthetically and tactilely pleasing surface.  
         [0028]    For example, the first and second materials  46  and  50  may be of the same material but of different colors, thereby producing a two-color, one-material trim panel  12 . Preferably, however, the first and second materials  46  and  50  are of different material. For example, the first material  46  is preferably a harder material, such as polypropylene, and the second material  50  is a softer material, such as TPU or thermoplastic elastomer (TPE). As shown in FIGS. 5 and 6, the first material  46  then conforms to the shape of the first cavity  40  and the second material conforms to the shape of the second cavity  42 , thereby forming the trim panel  12 . The trim panel  12  is then removed from the mold assembly  24  by any suitable method.  
         [0029]    An important aspect of the method of the invention is that the second step  22  may be performed prior to the third step  44 , or the third step  44  may be performed prior to the second step  22 . It has been discovered that such a method reduces costs by providing for the production of multiple trim panels using one mold assembly  24 , and substantially reduces trim panel assembly time.  
         [0030]    [0030]FIGS. 7 through 9 illustrate a first alternate embodiment of the mold assembly  24 ′ according to a first alternate embodiment of the method. The mold assembly  24 ′ is substantially identical to the mold assembly  24  shown in FIG. 2, except that the second mold half  28  of the mold assembly  24 ′ includes a movable core  36 ′. The core  36 ′ includes a fourth mold surface  54 , and a fifth mold surface  56 . The core  36 ′ is movable between a first position, as shown in FIG. 7, and a second position, (not shown). When in the second position, the core  36 ′ defines a second cavity  42 ′, and a third cavity or channel  58 , as shown in FIG. 9.  
         [0031]    A second step of a first alternate embodiment of the method of this invention is illustrated generally at  60  in FIG. 7, and is substantially identical to the second step  22 . In the second step  60  of the first alternate embodiment, the core  36 ′ is moved upwardly within the core cavity  34 , as viewed in FIG. 7, and into the first position. The first position is defined as a position wherein the fourth mold surface  54  of the core  36 ′ defines a portion of the second mold surface  32 , and the fifth mold surface  56  obstructs a portion of the second cavity  42 ′, shown in phantom line in FIG. 7. The fifth mold surface  56  thereby defines the channel  58 , as shown in FIGS. 8 and 9.  
         [0032]    A first material  46  is then introduced into the first cavity  40 ′ and the second cavity  42 ′. As described in regards to the second step  22 , both the first cavity  40 ′ and the second cavity  42 ′ are filled with the first material  46 . The first material  46  then conforms to the shape of the first cavity  40 ′ and the second cavity  42 ′, thereby forming the trim panel  12 . The trim panel  12  is then removed from the mold assembly  24  by any suitable method. As shown in FIG. 8, the trim panel  12  formed according to the first alternate embodiment of the method includes the channel  58  which has a shape corresponding to the shape of the fifth mold surface  56 .  
         [0033]    A third step of the first alternate embodiment of the method is not illustrated, but is substantially identical to the third step  44 . In the third step, the core  36 ′ is moved downwardly within the core cavity  34 , whereby the core  36 ′ obstructs the second cavity  42 ′, and into a second position (not shown). It will be understood, however, that in the second position, the mold surfaces  54  and  56  of the core  36 ′ will be substantially defined by the phantom line  42 ′.  
         [0034]    A material is then introduced into the first cavity  40 ′ through the first passage  48 . The material may be any suitable material, such as the first material  46 , or the second material  50 . Preferably the material is the first material  46 , and is molten plastic, such as polypropylene. The core  36 ′ is then is moved upwardly within the core cavity  34 , as viewed in FIG. 7, and into the first position, thereby exposing the second cavity  42 ′. The second material  50  is then introduced into the second cavity  42 ′, as shown in phantom line in FIG. 7. Preferably, the second material  50  is different from the first material  46 , thereby creating an accent region  18  having an aesthetically and tactilely pleasing surface. The trim panel  12  is then removed from the mold assembly  24 ′ by any suitable method, thereby exposing the channel  58 . A third material  62  is then mounted within the channel  58  by any suitable means, such as adhesive, hook and loop fasteners, or threaded fasteners. Preferably, the third material  62  is a decorative strip, such as plastic, fabric, or wood.  
         [0035]    It will be appreciated that the second step  60  of the first alternate embodiment may be performed prior to the third step, or the third step may be performed prior to the second step  60 .  
         [0036]    [0036]FIGS. 10 and 11 illustrate a second alternate embodiment of the mold assembly  102  according to a second alternate embodiment of the method. Typically, the mold assembly  102  includes a first mold half  104  and a second mold half  106 . The first mold half  104  includes a first surface  108 , and the second mold half  106  includes a second mold surface  110 . Although illustrated schematically in FIGS. 10 and 11, it will be appreciated that the mold surfaces  108  and  110  may be of any desired shape and contour. For example, first mold surface  108  might be a mold core, and second mold surface  10  might be a corresponding mold cavity. When in a closed position, as shown in FIG. 11, the first mold half  104  and the second mold half  106  form a first cavity  112 .  
         [0037]    The first mold half  104  includes a first portion  114 A of a core cavity  114 . The second mold half  106  includes a second portion  114 B of the core cavity  114  for slidably receiving a movable mold element or core  116 . The movable core  116  includes a first half  116 A, a second half  116 B and a core cavity  116 C. The core  116  is movable between a first position, as shown in FIG. 11, and a second position, as shown in FIG. 10. When in the second position, the core  116  defines a second cavity  118 , as shown in FIG. 10. When in the first position, the core cavity  116 C defines the second cavity  118 , as shown in FIG. 11.  
         [0038]    A second step of a second alternate embodiment of the method is not illustrated, but substantially identical to the second step  22 . In the second step of the second alternate embodiment, the core  116  is moved upwardly within the core cavity  114 , as viewed in FIG. 11, and into the first position. The first position is defined as a position wherein the core cavity  116 C is substantially aligned with the first cavity  112 . A first material  46  is then introduced into the first cavity  112  and the second cavity  118  through a first passage  119 . As described in regards to the second step  22 , both the first cavity  112  and the second cavity  118  are filled with the first material  46 . The first material  46  then conforms to the shape of the first cavity  112  and the second cavity  118 , thereby forming the trim panel  12 . The trim panel  12  is then removed from the mold assembly  102  by any suitable method.  
         [0039]    A third step of the second alternate embodiment of the method is illustrated generally at  100  in FIGS. 10 and 11. In the third step  100 , the core  116  is moved downwardly within the core cavity  114 , as viewed in FIG. 10, and into the second position. The first material  46 , or any desired material, is then introduced into the first cavity  112 . The core  116  is then is moved upwardly within the core cavity  114 , as viewed in FIG. 11, and into the first position, thereby exposing the second cavity  118 . A second material, such as the second material  50 , or any desired material, is then introduced into the second cavity  118 , as shown in FIG. 11. Preferably, the second material  50  is different from the first material  46 , thereby creating the accent region  18 , as shown in FIG. 1, having an aesthetically and tactilely pleasing surface.  
         [0040]    The trim panel  12  is then removed from the mold assembly  24  by any suitable method. For example, after the first mold half  104  is moved outwardly from the second mold half  106 , the first core half  116 A may be at least partially separated from the second core half  116 B so as allow removal of the trim panel  12  from the core cavity  116 C. It will be appreciated that the second step of the second alternate embodiment may be performed prior to the third step  100 , or the third step  100  may be performed prior to the second step.  
         [0041]    [0041]FIG. 12 illustrates a third alternate embodiment of the mold assembly  24 ″ according to a third alternate embodiment of the method. The mold assembly  24 ″ is substantially identical to the mold assembly  24  illustrated in FIG. 2, and will not be further described herein.  
         [0042]    A second step of the third alternate embodiment of the method of this invention is substantially identical to the second step  22  shown in FIG. 2. A third step of the third alternate embodiment of the method is illustrated generally at  200  in FIG. 12. In the third step, a fourth material can be introduced within the first cavity  40  or the second cavity  42 . The fourth material can be any suitable material such as a first insert  202  or a second insert  204 . The insert  202  can be any desired insert formed from any desired material, such as polypropylene or steel. Preferably, the first insert  202  is relatively rigid having a decorative or ornamental surface  206  that will be visible to a vehicle occupant. The first insert  202  can be positioned within a cavity  32 A formed in the mold surface  32 , or can be positioned such that the surface  206  is adjacent the mold surface  32 . Although only one first insert  202  in illustrated in FIG. 12, any desired number of first inserts  202  can be provided in the trim panel  12 .  
         [0043]    The second insert  204  can be any desired insert, such as a fastener. The insert  204  can be formed from any desired material, such as polypropylene or steel. Preferably, the second insert  204  is positioned such that the insert  204  will not be visible to a vehicle occupant, such as within the trim panel  12 , or opposite the surface  16 , as shown in FIG. 12. The second insert  204  can be positioned within a cavity  30 A formed in the mold surface  30 , positioned such that the insert  204  is adjacent the mold surface  30 , or positioned such that the insert  204  will be within the trim panel  12 . Although two second inserts  204  are illustrated in FIG. 12, any desired number of second inserts  204  can be provided in the trim panel  12 .  
         [0044]    The core  36  can remain in the first position, as shown in FIG. 12, so that a material can then be introduced into the first cavity  40  through the first passage  48 . The material may be any suitable material, such as the first material  46 , or the second material  50 . The material  46  or  50  thereby substantially surrounds the inserts  202  and  204 .  
         [0045]    Alternately, the core  36  can be moved downwardly into the second position, as shown in FIG. 4. A material, such as first material  46  or second material  50 , is then introduced into the first cavity  40 , as described above. The core  36  can then be moved upwardly within the core cavity  34 , and into the first position, thereby exposing the second cavity  42 . A desired material, such as the second material  50 , is then introduced into the second cavity  42 , as shown in phantom line in FIG. 12. Preferably, the second material  50  is different from the first material  46 , thereby creating the accent region  18 . The trim panel  12  is then removed from the mold assembly  200  by any suitable method.  
         [0046]    It will be appreciated that the second step of the third alternate embodiment may be performed prior to the third step  200 , or the third step  200  may be performed prior to the second step. It will be further appreciated that the third alternate embodiment can be performed using the mold  24 ′, as shown in FIG. 12, the mold  24 , as shown in FIG. 2, the mold  24 ′, as shown in FIG. 7, the mold  102 , as shown in FIG. 10, or any desired mold assembly.  
         [0047]    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.