INTERIOR TRIM FOAM PRODUCT AND METHOD OF FABRICATION THEREOF

Abstract: A vehicle interior part such as a glove box door or console door and its method of manufacture includes an outer shell backed by foam material which is bonded to a mold insert that reinforces the part and defines an exposed back. The insert includes a peripheral edge spaced with respect to a continuously formed raw peripheral edge of the shell and further includes a flange portion that is post formed so as to be bonded to and located in a net out relationship with the raw edge to define a finished surface appearance. The door is formed by a process that includes the steps of providing a composite plastic structure having a molded shell and foam component with an insert located in spaced relationship with respect to the shell to define a foamed cavity with a raw edge of foam and shell around the periphery of the composite member; providing a post formed flange on the insert and loading the shell, foam and insert components into a female nest; and heat die post forming of the flange to upset it into net out overlying relationship with both the raw edge of the shell and the exposed edge of foam formed in the composite part so as to produce a finished exterior surface on the composite part.

Description: The invention relates to a foamed interior trim products for the interior of a vehicle and its method of fabrication. More specifically, the invention is directed to a foamed article that includes a reinforcing insert configured and connected to an exterior shell component of a product to form a finished surface for connection to an interior vehicle body part. Vehicle parts are known which include an outer shell foamed in place with urethane foam. In such cases, in order to connect the part to a structural component of the the interior of a vehicle, an insert is provided to define a point for connection of the part by suitable fastening means to a vehicle interior part. An example of such composite structures is set forth in U.S.-A-3,123,403. In this arrangement, an automobile armrest is formed having two end portions thereon connected by screw fasteners to an interior body part. The point for connection of the armrest is an insert which is located on the interior of the automobile armrest. Such composite structures have a finished shell component connected by a backing layer of cellular foam to an insert. Both the shell and insert are located in a moulding apparatus in spaced relationship to form a cavity for the foam precursors which react to form the cellular backing for the shell and the bond connection between the insert and the shel. The moulded part is then joined to a separate backplate by suitable fastening means that connect to the insert and/or the shell to form an article which appears finished on both the interior and exterior portions of the final article. Composite structures like console or glove compartment doors can be configured to have shells formed from flexible polyvinyl chloride surfaces which blend with other components of a vehicle interior having a like covering. The backplate covers raw edges of the moulded insert and shell components. Consequently, there are no raw edges and foam flash that can catch clothes or the like when the door is opened. U.S.-A-3,620,566 discloses a passenger compartment armrest with a base plate held in place by welds. U.S.-A-3,773,875 discloses a method for manufacturing a foamed article. These Patents do not disclose the use of an insert to cover raw edges of an intermediate composite structure. One object of the present invention is to eliminate the need for a separate backplate component and the need for it to be fastened by suitable fastening means such as screws to foam moulded shell and insert components of the part. Typical vehicle interior trim parts to which the invention is applicable, the door panels, clusters, armrests, consoles and instrument panel pads of the type having a foamed in place core bonded to and backing an outer skin of flexible material such as polyvinyl chloride material which is reinforced by a mould insert part that is located during the moulding with respect to the raw edge of the outer shell to form a space therebetween into which the foam material is reacted and flowed to form a light weight cellular core. We propose providing means on the mould insert that will serve to both cover the raw edge of the skin and to net out the insert to the outer skin so as to define a back for the part which is also bonded to the cellular core, thereby to eliminate a separate backing plate and its fasteners. An insulated composite aluminium profile for a window or the like is disclosed in US-A-4525408. This is produced by placing two separate profile portions in a fixture, interconnecting the portions by plastic strips engaging grooves in the portions, to provide an enclosed spaced bounded by said portions and said strips, filling the space with an insulating plastic foam and, when the foam has expanded and cured, removing the profile from the fixture and deforming the grooves to fix the plastic strip therein. This patent does not disclose the use of a flexible shell having raw edges which are effectively covered by an insert which forms the backplate of the foam-filled product. According to one aspect of the present invention, there is provided a method of fabricating a vehicle interior trim component having a flexible outer shell and an insert which forms an integral back on the trim component comprising the steps of providing a mould cavity part having a support surface thereon; providing a mould cover and a tool insert means operatively associated to close the mould cavity part; providing a shell of flexible material having a raw peripheral edge thereon and supporting the shell by positioning the outer surface thereof on the support surface of the mould cavity part while spacing the raw peripheral edge from the mould cavity part to form a foam space providing a multisided, generally planar insert with a continuous peripheral edge an inner and outer surface, and an integral flange directed perpendicularly to the outer surface and formed in spaced parallelism inside the peripheral edge around the perimeter thereof to define side flanges and end flanges on the insert having lengths corresponding to that of the raw peripheral edge; locating the insert within the foam space to form a gap between the raw peripheral edge and the outer surface of the insert while locating the integral flange outside of the foam space and inboard of the raw peripheral edge; directing foam precursors into the foam space and the gap and reacting them therein so as to form a foam core in the foam space and the gap and to bond the inner surface of the insert and shell to the core; providing a post forming die, removing the foamed shell and insert from the mould cavity part and supporting the outer surface of the shell against the post forming die to locate the integral flange in an upwardly facing direction; thereafter applying a force against the integral flange to cause it to bend about ninety degrees to overlie the raw peripheral edge for holding the raw edge in place while covering both the raw peripheral edge and the gap formed between the raw peripheral edge and the insert. In accordance with another aspect of the present invention there is provided a vehicle interior trim component comprising an outer shell of flexible material having a raw edge formed continuously around the periphery thereof; a mould insert located in spaced relationship to the flexible shell including an inboard located peripheral edge thereon located in spaced relationship to the continuously formed peripheral raw edge of the shell; the insert being located in spaced relationship to the shell to form a cavity therebetween; foam material filling the cavity and the space between the raw edge and inboard periphery of the insert; and a heat post-formed outer flange on the insert located in overlying relationship to the outer surface of the shell to form a finished surface around the full periphery of both the shell and the insert whereby the insert is connected to the shell to form an exposed back on the shell for supporting both it and the foam material. Embodiments of the invention will now be described by way of example with reference to the accompanying drawings in which: Figures 1 to 3 are diagrammatic views of mould tooling to form a composite structure including an outer shell and mould insert component to provide a cellular foam backing with respect to the shell; Figure 2a is a fragmentary view of an alternative gate location; Figure 4 is a perspective view of a composite plastic door structure; Figure 4a is as fragmentary view of a corner of the structure; Figure 5 is a section view of an insert component of the composite structure formed in the mould tooling of Figures 1 to 3; Figure 6 is a sectional view of the composite structure made by the moulding apparatus of Figures 1 to 3; and Figure 7 is a sectional view of a heat die formation of the insert to form a raw edge cover in the door structure of Figure 4; and Figures 8A - 8D are diagrammatic views of a hot air heater and roller assembly for practicing a second method of the invention. The article of the present invention and its method of manufacture will be described with reference to a composite plastic door such as a glove box door or a console door for use in association with the interior automotive body assembly. Figure 4 shows a representative type of glove compartment door 10. The door includes an outer shell or skin 12 of flexible grained polyvinyl chloride material which can be formed by a process of the type set forth in U.S. Patent No. 4,562,032 thereby to retain a highly grained appearance on the exterior shell face 14. An insert 16 forms the back of the door 10. The mould tooling apparatus in the present invention is configured as shown in Figures 1 to 3 to form a preformed part. A cover 18 of the mould apparatus supports the mould insert 16 in spaced relationship to a mould cavity part 20. Alternatively, the insert 16 can be preloaded as shown in dotted line at 16a in Figure 2. Cavity part 20 supports the outer shell 12. More specifically, the insert 16, as shown in Figures 1 and 5, is a plastic part having a planar extent 24 substantially equal to that of an opening 26 in the outer shell 12 which is defined by a raw edge 28 formed thereon around the periphery of the outer shell 12. The insert 24 includes a peripheral edge 30 that is located by the mould cover 18 to be located in close spaced relationship to the raw edge 28 which is turned thereover by pivotal tool inserts and/or slides 32 as shown in Figures 2 and 3 to cover the edge 30. The insert 24 more particularly includes an integral post formed flange 34 with segments 34a on the sides and 34b on the ends of the insert 24 to be located in close relationships with the distal end of the raw edge 28. Each segment 34a, 34b is arranged generally perpendicularly with respect to a planar extent 35 on the insert 24. The cover 32 is closed and sealed with respect to the mould cavity part 20. The insert 24 includes an opening 36 for receiving foam precursors from a foam pour nozzle 38 which will feed the foam precursors into a cavity 40 formed between the mould supported outer shell 12 and the mould supported insert 24. The foam precursors react within the cavity and flow into a peripheral space 41 formed around the spaced insert 24 and the shell at the outer edges thereof. Following reaction of the foam, an intermediate composite structure 42 is removed from the moulding apparatus of Figure 1 which is of the configuration shown in Figure 6. The intermediate composite structure 42 thus includes an exterior surface defined by the outer shell 12. On the back side of the part, a raw edge of foam and vinyl are formed continuously around the insert 24 at a point adjacent the vertical flange 34 thereon. After completing the intermediate composite structure 42, it is loaded into a heated die assembly 44. More particularly, the outer or exterior face 14 of the outer shell 12 is rested against the inner surface 46 of a female nest 48. The female nest is configured to support the exterior shell face 14 so that it will remain unblemished during the post forming operation. The post forming operation includes applying a heated die 50 against the flange 34 to cause it to be post formed from its vertical position. More particularly, the heat die includes a curved surface 52 thereon that will engage the distal end of the flange 34 as the heated die 50 is moved progressively toward the female nest. The curved surface 25 progressively deflects the flange 34 in an outward direction into an overlying relationship with the raw edge 28 until the face 54 of the flange 34 is juxtaposed against the outboard peripheral surface 56 of the outer shell 12. The heated die maintains heat and pressure on the post formed flange 34 to cause it to net out to the outer shell 12 and to form a continuously formed connector flange 58 that covers the raw edge 28 and the exposed foam portions 59 of the intermediate composite structure 42 a net out condition interface therebetween. The pour opening 36 in the insert is covered by a decorative plug 60. Alternatively, an end gate can be provided which is covered under the post formed flange 34 at the hinge mounting surface 64 by providing a notch in the edge of shell 12 and a hole 61 through insert 12 at the notch. In such case, the need for a decorative plug is eliminated. The glove compartment door 10 thus includes a back which has a finished appearance without raw edges. The construction eliminates the need for a separate backing plate and fasteners for securing such a separating backing plate to the insert. Nevertheless, because of the illustrated arrangement, the formed connector flange 58 can serve as a structural component for the connection of a hinge assembly 62. More particularly, the longitudinal reach 64 of the connector flange is arranged to support a first hinge plate 66. The first hinge plate 66 is connected to the connector flange by a suitable fastening means such as screws 68 that can not only be connected to the connector flange 58, but can extend therethrough to be fastened to the inboard segment of the insert 16 which underlies the formed connector flange 58. The second hinge plate has holes therein that will receive suitable fastening means for connecting the second hinge plate to a structural portion of the vehicle interior to locate the door 10 in an open or closed position with respect to a glove compartment opening. Figures 8A to 8D show steps of a second method embodiment. The flange 34 is first heated by hot air from blower 17 until it is in a reformable state. At this point a series of rollers 72 are sequentially passed over the flange 34 to cause it to be post formed over the raw edge of a shell. The invention herein has been described in an illustrative manner and it is understood that the terminology which has been used is intended to be in the nature of words of description rather than or limitation.

Claims: A method of fabricating a vehicle interior trim component (10) having a flexible outer shell and an insert which forms an integral back on the trim component comprising the steps of providing a mould cavity part (20) having a support surface thereon; providing a mould cover (18) and a tool insert means (32) operatively associated to close the mould cavity part; providing a shell (12) of flexible material having a raw peripheral edge (28) thereon and supporting the shell by positioning the outer surface thereof on the support surface of the mould cavity part while spacing the raw peripheral edge from the mould cavity part to form a foam space (40); providing a multisided, generally planar insert (16) with a continuous peripheral edge (30), an inner and outer surface, and an integral flange (34) directed perpendicularly to the outer surface and formed in spaced parallelism inside the peripheral edge around the perimeter thereof to define side flanges (34A) and end flanges (34B) on the insert having lengths corresponding to that of the raw peripheral edge; locating the insert within the foam space to form a gap (41) between the raw peripheral edge and the outer surface of the insert while locating the integral flange outside of the foam space and inboard of the raw peripheral edge; directing foam precursors into the foam space and the gap and reacting them therein so as to form a foam core in the foam space and the gap and to bond the inner surface of the insert and shell to the core; providing a post forming die (44); removing the foamed shell and insert from the mould cavity part and supporting the outer surface of the shell against the post forming die to locate the integral flange in an upwardly facing direction; thereafter applying a force against the integral flange to cause it to bend about ninety degrees to overlie the raw peripheral edge for holding the raw edge in place while covering both the raw peripheral edge and the gap formed between the raw peripheral edge and the insert. A method according to claim 1 characterised by providing a source (70) of hot air and roller means (72), impinging the hot air against the flange (34) to apply heat thereon, and applying pressure thereon by the roller means to cause the flange to post-form into overlapping relationship with the raw edge (28) of the shell (12). A method according to claim 1, characterised by providing a heated die (44) and utilising the heated die to apply a compression force on the flange (34) to cause it to post-form into overlapping relationship with the raw edge of the shell (12). A method according to any preceding claim, characterised by locating the inset (16) with respect to the shell (12) by preloading the insert into the mould cavity part (20). A vehicle interior trim component (10) comprising an outer shell (12) of flexible material having a raw edge (28) formed continuously around the periphery thereof; a mould insert (16) located in spaced relationship to the flexible shell including an inboard located peripheral edge (30) thereon located in spaced relationship to the continuously formed peripheral raw edge of the shell; the insert being located in spaced relationship to the shell to form a cavity (40) therebetween; foam material filling the cavity and the space between the raw edge and inboard periphery of the insert; and a heat post-formed outer flange (58) on the insert located in overlaying relationship to the outer surface of the shell to form a finished surface around the full periphery of both the shell and the insert whereby the insert is connected to the shell to form an exposed back on the shell for supporting both it and the foam material. A component according to claim 5, wherein the insert has a plug opening (36) therein forming a foam pour hole for supplying foam precursors into the cavity (40); decorative plug means (60) for closing the foam pour hole in the finished product; and hinge means (62) including a first portion (66) thereon overlying a longitudinal segment of the heat post-formed flange (34) on the insert and further including a second portion thereon hinged with respect to the first portion; and fastening means (68) for securing the hinge means to the longitudinal portion of the heat post-formed flange portion of the insert.

Inventors: LABRIE, CRAIG B.
Applicants: DAVIDSON TEXTRON INC.
Application year: 1988
Main classification: B29C67
IPC codes: B29C44, B29C33, B29C65