Apparatus and method for moulding a multilayered trim component

Abstract: A method and apparatus (10) for moulding a multilayered automotive trim component (12) having a covered edge portion (60). A flexible covering (32) is positioned between opposable moulds (14, 16) that are continuously operable between an open position and a closed position. First and second article shaping surfaces (18, 20) on the moulds (14, 16) form the article surfaces. An extendible slide (22, 23) having a cover receiving surface (24, 25) is positioned between the moulds (14, 16) such that the cover receiving surface (24, 25) is positioned inwardly of a perimeter portion (26) of the first article shaping surface (18). The slide (22, 23) is extended and a polymeric resin (48) is injected onto the second article-shaping surface (20). The moulds (14, 16) are closed such that the first and second article-shaping surfaces (18, 20) and the cover-receiving surface (24, 25) together define a cavity (52). The resin (48) is compressed within the cavity (52) and urges the covering (32) against the first article-shaping surface (18) and the cover-receiving surface (24, 25) to form a substrate layer (56) having a first covered surface (58) conforming to the first article-shaping surface (18) and a second covered surface (60) conforming to the cover-receiving surface (24, 25). The second covered surface (60) is generally opposite of the first covered surface (58). The slide (22, 23) is retracted sufficiently to remove the component (12) from the moulds (14, 16).

Description: This invention relates to moulding an automotive trim component having a rigid substrate layer and a flexible covering. More particularly, the invention relates to an apparatus and method for moulding the flexible covering around an edge of the rigid substrate. Automotive trim components, such as door panels, instrument panels and consoles, typically have a multilayered structure comprising a rigid polymeric substrate layer and a decorative flexible covering. Low pressure moulding, or compression injection moulding, is currently used in the manufacture of these components to integrally mould the flexible covering to a surface of the substrate layer. An advantage of the low pressure moulding process is that the layers can be moulded simultaneously. No pre-forming of either the covering or the substrate is required. Heretofore, however, low pressure moulding equipment has not included in-mould means for folding the covering around the perimeter edges of the substrate. Therefore, a separate edge folding operation has typically been conducted, following the removal of the component from the moulding equipment, to improve the appearance of the component for automotive interior applications. In this operation, the ends of the covering are folded around the perimeter edges of the substrate and affixed to a surface opposite the covered surface of the substrate. This process is accomplished manually, by mechanical means through the use of auxiliary equipment, or by a combination of the two methods. The use of primers and adhesives is typically required to secure the ends of the covering to the substrate. Alternatively, when the covering includes a foam backing, the covering may be secured to the substrate by heating the foam and fusing it to the substrate. While this heating method eliminates the need for primers and adhesives, the method still requires significant post-mould processing, and material selection is limited to compatible foams and substrates. While not teaching low pressure moulding or edge folding, U.S. Patent No. 3,661,684, issued to Rallis et al. (Rallis) teaches moulding an upholstered article in a single mould. Sliding sealing bars secure a covering to a thermoplastic cap sheet and are then retracted to remove the upholstered article from the mould. The slide creates a hidden seam between the covering and cap sheet. Rallis does not teach simultaneously moulding and covering the edges of a rigid substrate nor using slides to impart shape to the substrate. The specification of WO 94/03337 describes a paint film which is applied as a surface finish to an automobile part. The paint film is applied to a deeply-drawn injection moulded part during moulding by placing the paint film in an injection mould with a liner layer facing a cavity of the mould. A flowable resin is injected into a space on the opposite side of the film from the cavity such that the film is urged into contact with the surface of the cavity. The film adheres to he injected resin to result in a paint film covered injection moulded object. Slides are used to provide undercut surfaces on the object covered by paint film. DE-A-41 27 241 describes a method of making an automotive part having an injection moulded substrate and a decorative covering layer. The mould used for producing the component includes slides that can be moved to pinch an excess portion of the covering between the slides and the article shaping surfaces of the mould. The slides have a curved surface so as to enable the article to be moulded with a curved edge. According to the present invention, there is now provided a method of moulding a multilayered automotive trim component having a rigid substrate layer and a flexible covering, comprising the steps of: positioning said covering between opposable moulds continuously operable between an open position and a closed position, wherein said moulds have first and second article-shaping surfaces and said first article-shaping surface has a perimeter; extending a slide having a cover-receiving surface between said moulds such that said cover-receiving surface is positioned inwardly of said perimeter; injecting a polymeric resin onto said second article-shaping surface; closing said moulds such that said first and second article-shaping surfaces and said cover-receiving surface together define a cavity wherein said resin compresses and urges said covering against said first article-shaping surface and said cover-receiving surface to form a substrate layer having a first covered surface and conforming to said first article-shaping surface and a second covered surface conforming to said cover-receiving surface, said second covered surface being generally opposite said first covered surface; and retracting said slide such that said cover-receiving surface is positioned outwardly of said perimeter to permit removal of said component from said moulds ; the method being characterised in that; the covering includes an outer layer and a backing, the step of positioning the covering between opposable moulds is such that the outer layer faces said first article-shaping surface, said slide has an indented portion and the said cavity has a pocket defined by the second article-shaping surface and the indented portion, the step of extending a slide having a cover receiving surface between said moulds such that said cover-receiving surface is positioned inwardly of said perimeter causes an excess portion of the covering to be pinched between the slide and the second article-shaping surface, the cover-receiving surface is provided with a concave curved portion to reduce stretching of said covering during moulding of an edge of the substrate layer, the step of closing the moulds compresses the resin and urges the covering against the first article-shaping surface, the cover-receiving surface and the indented portion, the resin impregnating the backing in the pocket, the method including the further steps of forming flash on a portion of the covering, the covered flash portion conforming to the pocket and providing a rigid cutting surface, and trimming the covered flash portion from the component, the trimming being facilitated by the said rigid cutting surface. An alternative embodiment of the invention teaches moulding the component with a covered flash portion. A pocket between the slide and the second article-shaping surface receives resin to form the covered flash portion. The flash provides a rigid backing to assist in removing the excess covering. The method and apparatus of the present invention permit the manufacture of covered substrates having a nearly finished edge. The component includes a second covered surface generally opposite the first decorative surface of the component. The first and second surfaces are simultaneously integrally moulded to the substrate. The final finishing process merely requires trimming an excess portion of covering. The invention eliminates the need for adhesives, fasteners or post moulding folding operations. The resulting component is more economical to produce and displays a neat edge appearance. These and other benefits of the present invention are more fully described below. The invention will now be described further, by way of example, with reference to the accompanying drawings, in which: Figure 1 is a cross-sectional view of an apparatus having opposable moulds and movable slides, wherein the moulds are open and the slides are retracted; Figure 2 is a cross-sectional view of the apparatus illustrated in Figure 1, showing the extension of the slides and the injection of a substrate resin while the moulds are in a partially closed position; Figure 3 is a cross-sectional view of the apparatus illustrated in Figure 1, showing the moulding of a trim component; Figure 4 is an enlarged view of the area labelled 4 in Figure 3; Figure 5 is an enlarged view of the area labelled 5 in Figure 3, showing an alternative embodiment of the invention; and Figure 6 is a cross-sectional view of a finished trim component. Figures 1-3 illustrate an apparatus 10 for the low pressure moulding of multilayered automotive trim component 12. Apparatus 10 comprises opposable moulds 14, 16 having first and second article-shaping surfaces 18, 20. Moulds 14, 16 are operable by a hydraulic press (not shown) through a continuous range of positions from an open position to a closed position. Figures 1, 2 and 3 show moulds 14, 16 in an open position, a partially closed position and a closed position, respectively. Apparatus 10 further comprises slides 22, 23 having cover-receiving surfaces 24, 25. Slides 22, 23 are movable between moulds 14, 16 such that cover-receiving surfaces 24, 25 are positioned inwardly of perimeter 26 of article-shaping surface 18 when slides 22, 23 are in an extended position and outwardly of perimeter 26 when slides 22, 23 are in a retracted position. Hydraulic cylinders 28 operate to extend and retract slides 22, 23. Cylinders 28 may be mounted vertically, as shown, or horizontally. The extending and retracting movement of slides 22, 23 is guided through the provision of appropriate guideways as indicated at 30 in Figures 1-3. Additional features of apparatus 10 will be described hereinbelow in relation to the process steps illustrated in Figures 1-5. Referring first to Figure 1, apparatus 10 is shown with moulds 14, 16 in an open position. Flexible covering 32, which comprises an outer layer 42 and a backing 44, is positioned by retainers 34 between moulds 14, 16 such that outer layer 42 faces article-shaping surface 18. Retainers 34 are mounted to mould 14 outwardly of perimeter 26 and secure excess portions 36 of covering 32. Retainers 34 extend through slots 38, 40 provided in slides 22, 23. Slots 38, 40 have a width greater than or equal to the distance travelled by slides 22, 23 in moving between the extended and retracted positions. Figure 1 shows slides 22, 23 in a retracted position. Alternatively, one or both slides 22, 23 could be extended prior to the positioning of covering 32. Figure 2 shows slides 22, 23 moving to an extended position and moulds 14, 16 in a partially closed position. A polymeric resin 48 is injected through resin inlets 50 onto article-shaping surface 20. Resin 48 may be injected while the moulds are fixed a suitable distance apart in a partially closed position, or alternatively, resin 48 may be injected as moulds 14, 16 move to a closed position. Resin 48 is completely injected before moulds 14, 16 reach the closed position. One or both slides 22, 23 may be extended before resin 48 is injected. Alternatively, slides 22, 23 may be extended and resin 48 injected simultaneously. The precise timing of slide extension, mould closing and resin injection is dependent on the component shape, resin inlet location and the elasticity of covering 32. Extension of slides 22, 23 causes excess portion 36 to be pinched between the slides and second article-shaping surface 20 as shown in Figure 3. Delaying the slide extension permits more of covering 32 to be drawn into the moulds and reduces stretching of covering 32. Early slide extension pinches excess portion 36 and increases the amount of stretching applied to cover 32. When moulds 14, 16 reach a closed position, article-shaping surfaces 18, 20 and cover-receiving surfaces 24, 25 cooperate to define a mould cavity 52. Slides 22, 23 are fully extended and pinch covering 32 between the slides and second article-shaping surface to seal cavity 52 and prevent the escape of resin from the moulds. Resin 48 is compressed and urges covering 32 firmly against article-shaping surface 18 and cover-receiving surfaces 24, 25. The compression pressure is dependent on material selection, the size and shape of the article, the resin fill volume, and the moulding temperatures. To prevent slides 22, 23 from moving outward while compression pressure is being applied, vertically mounted cylinders 28 are equipped with locking mechanisms 54 which seat in mould 16. Upon cooling, resin 48 forms rigid substrate layer 56. As shown in Figure 4, substrate layer 56 is moulded such that it has a first covered surface 58 conforming to article-shaping surface 18 and a second covered surface 60 conforming to cover-receiving surface 24. Covered surface 60 is generally opposite covered surface 58. Figure 4 further shows a concave curved portion 62 and an elongated portion 64 of cover-receiving surface 24. Curved portion 62 is provided to reduce the stretching of covering 32 during the moulding of edge 65 of substrate layer 56. The actual curvature of portion 62 will be determined by the stretch characteristics of covering 32. Generally, a low stretch material will require a larger radius of curvature than a high stretch material. Elongated portion 64 is located inwardly of curved portion 62 and is sized to form a second covered surface of a desired length. As illustrated in Figures 4 and 5, covering 32 has an unbonded excess portion 36 that extends beyond second covered surface 60. Excess portion 36 seals the space between slides 22, 23 and mould 16 during the moulding process. Figure 5 shows another embodiment of the invention in which slide 23 has an indented portion 68 positioned inwardly of cover-receiving surface 25. Indented portion 68 and article-shaping surface 20 together define a pocket 70 within mould cavity 52. As moulds 14, 16 move to a fully closed position, compressed resin 48 flows into pocket 70 and urges covering 32 against indented portion 68. Upon cooling, resin 48 and covering 32 in pocket 70 combine to form a covered flash portion 76. Because of the relative size, compression pressure in pocket 70 is generally greater than the pressure within cavity 52. Resin partially embeds into backing 44 and provides a firm base for latter trimming operations. After component 12 has sufficiently cooled, slides 22, 23 are retracted to permit removal of component 12 from moulds 14, 16. Component 12 includes excess portion 36 of covering 32 and optionally also includes covered flash portion 76. Both excess portion 36 and flash portion 76 can then be trimmed off to finish component 12. Various conventional cutting means may be used, including water jets, hot knives, and punch presses. Components having a flash portion 76 advantageously provide a rigid cutting surface to facilitate the trimming operation and better resist delamination between covering 32 and substrate 56. Resin impregnating backing 44 during the moulding of flash portion 76 makes the backing less elastic and less prone to being exposed in the event of shrinkage of covering 32. Figure 6 shows component 12 following the trimming operation. As illustrated, covering 32 contains outer layer 42 and backing 44. A wide variety of materials may be used for outer layer 42, including thermoplastic materials, leather, suede and cloth. Suitable thermoplastic materials include polyolefins, thermoelastomers and vinyls. Suitable materials for backing 44 include thermoplastic foams and cloth. Suitable materials for rigid substrate layer 56 include polymeric resins such polypropylene. While the present invention has been illustrated using two slides, it will be readily apparent to those ordinarily skilled in the art that the number of slides required will depend on the component to be moulded. In addition, while the slides are illustrated as extending and retracting in a direction substantially perpendicular to the draw of the moulds, the slides could, alternatively, be extended and retracted at another angle in order to change the shape of the second covered surface. Furthermore, although the retainers 34 have been illustrated as pins mounted to mould 14, various alternative retaining means may be used. For example, the pins could be mounted to a spring-loaded frame to reduce the stretching of the covering that occurs during the closing of the moulds. In addition, clamps or pincers could be used in place of pins. These pincers could be actuated by a hydraulic cylinder to modify the clamping pressure during the course of the process.

Claims: A method of moulding a multilayered automotive trim component (12) having a rigid substrate layer (56) and a flexible covering (32), comprising the steps of: positioning said covering between opposable moulds (14,16) continuously operable between an open position and a closed position, wherein said moulds (14,16) have first and second article-shaping surfaces (18,20) and said first article-shaping surface (18) has a perimeter (26); extending a slide (22,23) having a cover-receiving surface (24,25) between said moulds (14,16) such that said cover-receiving surface is positioned inwardly of said perimeter (26); injecting a polymeric resin (48) onto said second article-shaping surface (20); closing said moulds (14,16) such that said first and second article-shaping surfaces (18,20) and said cover-receiving surface (24,25) together define a cavity (52) wherein said resin (48) compresses and urges said covering (32) against said first article-shaping surface (18) and said cover-receiving surface (24,25) to form a substrate layer (56) having a first covered surface (58) and conforming to said first article-shaping surface (18) and a second covered surface (60) conforming to said cover-receiving surface (24), said second covered surface (60) being generally opposite said first covered surface (58); and retracting said slide (22,23) such that said cover-receiving surface (24,25) is positioned outwardly of said perimeter (26) to permit removal of said component (12) from said moulds (14,16); the method being characterised in that ; the covering includes an outer layer (42) and a backing (44), the step of positioning the covering between opposable moulds (14,16) is such that the outer layer (42) faces said first article-shaping surface (18), said slide (22,23) has an indented portion (68) and the said cavity (52) has a pocket (70) defined by the second article-shaping surface and the indented portion (68), the step of extending a slide (22, 23) having a cover receiving surface (24,25) between said moulds (14,16) such that said cover-receiving surface is positioned inwardly of said perimeter (26) causes an excess portion (36) of the covering (32) to be pinched between the slide (22,23) and the second article-shaping surface (20), the cover-receiving surface (24,25) is provided with a concave curved portion (62) to reduce stretching of said covering (32) during moulding of an edge (65) of the substrate layer (56), the step of closing the moulds (14,16) compresses the resin and urges the covering (32) against the first article-shaping surface (18), the cover-receiving surface (20) and the indented portion (68), the resin impregnating the backing (44) in the pocket (70), the method including the further steps of forming flash on a portion (76) of the covering, the covered flash portion (76) conforming to the pocket (70) and providing a rigid cutting surface, and trimming the covered flash portion (76) from the component, the trimming being facilitated by the said rigid cutting surface. A method as claimed in claim 1, further comprising the step of trimming said excess portion (36) from said component. A method as claimed in claim 1, wherein said slide has an indented portion (68) and said step of closing said moulds (14,16) further causes said resin (48) to form a covered flash portion (76) on said substrate (56), said flash portion (76) conforming to a pocket (70) defined by said second article-shaping surface and said indented portion (68), the method further comprising the step of trimming said covered flash portion (76) from said component. A method as claimed in claim 1, wherein the step of extending said slide (22,23) occurs before the step of injecting said resin (48). A method as claimed in claim 1, wherein the step of extending said slide (22,23) and the step of injecting said resin (48) occur simultaneously. A method as claimed in claim 1, wherein said moulds (14,16) are further continuously operable between an open position and a partially closed position, and wherein said resin injecting step occurs while said moulds (14,16) are in a partially closed position. An apparatus for moulding a multilayered automotive trim component having a rigid polymeric substrate layer (56) and a flexible covering (32), comprising: a first mould (14) having a first article-shaping surface (18) for forming a first covered surface (58) of said substrate (56), said first article-shaping surface (18) having a perimeter (26); a second mould (16) having a second article-shaping surface (20), said first and second moulds (14,16) being opposable and continuously operable between an open position and a closed position; a slide (22,23) having a cover-receiving surface (24,25) for forming a second covered surface (60) of said substrate (56), said second covered surface (60) being generally opposite said first covered surface (58), said slide (22,23) being movable between said moulds (14,16) such that said cover-receiving surface (24,25) is positioned inwardly of said perimeter (26) when said slide (22,23) is in an extended position and outwardly of said perimeter (26) when said slide (22,23) is in a retracted position, said first and second article-shaping surfaces (18,20) and said cover-receiving surface (24,25) together defining a cavity (52) when said moulds (14,16) are closed and said slide (22,23) is extended; and a resin inlet (50) to said second article-shaping surface (20) for injecting resin (48) to form said component (12); characterised in that said slide (22,23) is movable to pinch an excess portion of the flexible covering (32) between the slide (22,23) and the second article-shaping surface (20); and the cover receiving surface (24,25) is provided with a concave curved portion (62) to reduce stretching of said covering (32) during moulding of an edge (65) of the substrate layer (56). An apparatus as claimed in claim 7, wherein said slide (22,23) further comprises an indented portion (68) inwardly of said cover-receiving surface (24,25) such that when said first and second moulds (14,16) are closed and said slide (22,23) is extended said indented portion (68) and said second article-shaping surface together define a pocket (70) within said cavity for forming a covered flash portion (76) on said substrate layer (56).

Inventors: LUCKETT THOMAS, MIKLAS JOHN, LUCKETT, THOMAS, MIKLAS, JOHN
Applicants: FORD MOTOR CO, FORD MOTOR COMPANY
Application year: 1995
Main classification: B29C45
IPC codes: B29C45, B29C43, B29C37, B29C70