Abstract:
A method for manufacturing a multi-shot interior trim component within a mold tool, comprising the steps of moving a first mold portion adjacent a second mold portion to define a potential cavity volume; modifying the potential cavity volume to define a first reduced cavity volume; depositing a first material in the first reduced cavity volume; further modifying the potential cavity volume to define a second reduced cavity volume, wherein at least a localized portion of the first deposited material is utilized to define, with the mold tool, the second reduced cavity volume; providing a rib on one of the first and second mold portions; exposing the rib to one of the first and second reduced cavity volumes; depositing a second material in the second reduced cavity volume; attaching the second deposited material to the first deposited material at least proximate the localized portion of the first deposited material, wherein one of the first and second materials defines a substrate portion having an outboard surface, an inboard surface, a chute portion extending from the outboard surface, wherein the chute portion defines an axial opening, and, wherein, the other of the first and second materials defines an inflatable restraint door that closes-out the axial opening formed in the substrate portion to define an interior trim component of a vehicle; and defining the inflatable restraint door to include a pre-weakened portion corresponding to the rib of one of the first and second mold portions.

Description:
RELATED APPLICATIONS 
       [0001]    This application claims the benefit of earlier filed U.S. Provisional Application Ser. No. 60/868,202, filed Dec. 1, 2006, which is incorporated herein by reference in its entirety. 
     
    
     BACKGROUND 
       [0002]    1. Technical Field 
         [0003]    The invention relates to a method for manufacturing a multi-shot component and to a method for manufacturing a multi-shot interior trim panel that forms an inflatable restraint door integrated with the trim panel. 
         [0004]    2. Description of Related Art 
         [0005]    It is known in the art that inflatable restraints, which are commonly referred to as “airbags,” have been included in automotive vehicles to reduce the potential for occupant injury during an accident situation. It is also known in the art that the design of automotive interior trim panels, such as, for example, instrument panels, have included pre-weakened areas, chute portions, and the like relative a mounting location of the inflatable restraint. 
         [0006]    When including an inflatable restraint behind an instrument panel, conventional instrument panel assemblies have often included one or more layers in a multi-layer structure that included, for example, a rigid substrate layer, an intermediate foam layer, and a skin layer. One or more of these layers may be pre-weakened and include a reinforcing scrim, steel plate, or the like disposed there-between to define an inflatable restraint door integrated with the instrument panel that permits passage of the inflatable restraint there-through when the inflatable restraint is inflatably-expanded into the passenger compartment area on the opposite side of the instrument panel. 
         [0007]    Due to competitive design standards in the automotive industry, customer demand has resulted in the expectation that interior trim panels, such as, for example, instrument panels, have a seamless inflatable restraint door (i.e. the instrument panel appears to have a continuous surface without any parting lines to visibly-locate and identify an inflatable restraint door). To achieve this design, it is known in the art that conventional interior trim panels include pre-weakened tear seams or strips that are formed in the outboard surface of the interior trim panel. 
         [0008]    In addition to these design expectations, global competitive forces demand that material and manufacturing costs are reduced to provide a supplier and manufacturer with a profit. As such, a need currently exists to provide an interior trim panel that is reduced in components and manufacturing/design complexity while also maintaining, if not improving, overall performance of the interior trim panel. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    The present disclosure will now be described, by way of example, with reference to the accompanying drawings, in which: 
           [0010]      FIG. 1  is a perspective view of a multi-shot trim component including a seamless inflatable restraint door in accordance with an exemplary embodiment of the invention; 
           [0011]      FIG. 2  is a partial perspective view of a partially-formed a multi-shot trim component of  FIG. 1  including a first material in accordance with an exemplary embodiment of the invention; 
           [0012]      FIG. 3  is a partial perspective view of the partially-formed the multi-shot trim component of  FIG. 2  including a second material to form the a multi-shot trim component of  FIG. 1  in accordance with an exemplary embodiment of the invention; 
           [0013]      FIG. 4A  is a cross-sectional view of the multi-shot trim component of  FIG. 3  according to line  3 - 3  in accordance with an exemplary embodiment of the invention; 
           [0014]      FIG. 4B  is a cross-sectional view of the multi-shot trim component of  FIG. 3  according to line  3 - 3  in accordance with an exemplary embodiment of the invention; 
           [0015]      FIGS. 5A-5D  each illustrate partial perspective views of the multi-shot trim component of  FIG. 1  in accordance with an exemplary embodiment of the invention; 
           [0016]      FIGS. 6A-6C  illustrate a method for manufacturing the multi-shot trim component of  FIG. 1  in accordance with an exemplary embodiment of the invention; and 
           [0017]      FIGS. 7A-7C  illustrate a method for manufacturing the multi-shot trim component  FIG. 1  in accordance with an exemplary embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0018]    The figures illustrate an exemplary embodiment of a method for manufacturing a multi-shot component, such as, for example, an interior trim panel in accordance with an embodiment of the invention. In an embodiment, the interior trim panel includes a first material that is shaped to provide an opening that permits passage of an inflatable restraint through the interior trim panel and a second material that is disposed over the opening formed in the first material to provide a closure panel/inflatable restraint door that closes-out the opening formed in the interior trim panel. 
         [0019]    For brevity, the disclosure hereof will illustrate and describe an interior trim panel that provides an instrument panel having an inflatable restraint door, but it is appreciated that the interior trim panel could be shaped to define any type of an interior trim panel other than an instrument panel, such as, for example, door panels, a headliner trim panel, center consoles, overhead consoles, a pillar trim panel, or the like that seamlessly provides an inflatable restraint door in the interior trim panel. Based on the foregoing, it is to be generally understood that the nomenclature used herein is simply for convenience and the terms used to describe the invention should be given the broadest meaning by one of ordinary skill in the art. 
         [0020]    Referring now to  FIG. 1 , an interior trim panel is shown generally at  10 ,  100  according to an embodiment. According to the illustrated embodiment, the interior trim panel  10 ,  100  is an instrument panel including a plurality of openings that are shown generally at  12 - 22  and one or more recessed bezels (i.e., one or more depressions) that are shown generally at  24 ,  26 . Although the interior trim panel  10 ,  100  is shaped to form an instrument panel, it will be appreciated that the invention not limited to an instrument panel and that the interior trim panel  10 ,  100  may include, for example, door panels, a headliner trim panel, center consoles, overhead consoles, a pillar trim panel, or the like. 
         [0021]    As is known in the art, an instrument panel  10 ,  100  is installed on a frame (not shown) proximate an area underneath a windshield (not shown) and between the engine compartment (not shown) and a passenger compartment (not shown) of a vehicle. According to an embodiment, the instrument panel  10 ,  100  includes an engine-compartment-facing outboard side  28  and a passenger compartment-facing inboard side  30  that places, within reach and direct sight of the occupants of the vehicle, a plurality of components/devices (not shown) associated with the plurality of openings  12 - 22  and the one or more recessed bezels  24 ,  26 . According to an embodiment, the inboard side  30  may include an aesthetically pleasing color and texture, such as, for example, a soft, elastic feel, or alternatively, a relatively hard, rigidified feel, or, alternatively, a combination of a soft and hard feel. 
         [0022]    As illustrated in  FIG. 1 , the openings  12 - 22  formed in the instrument panel  10 ,  100  may provide a variety of features that may be controlled, manipulated, adjusted, or otherwise interfaced with by a passenger. For example, the opening  12  may provide a passage that permits an inflatable restraint  11  ( FIGS. 4A and 4B ) to inflate and pass there-through from the outboard side  28  of the instrument panel  10 ,  100  to the inboard side  30  of the instrument panel  10 ,  100 . According to an embodiment, the remaining openings  14 - 22  may provide an air duct port for a heating-ventilation-and-air-conditioning (HVAC) system, an opening for a storage receptacle, such as, for example, a glove box, an opening for mounting radio/compact disc (CD)/digital video disc (DVD)/HVAC controls, and the like. The bezel  26  may form a depression in the inboard side  30  of the instrument panel  10 ,  100  to provide a map pocket, coin tray, ash tray, or the like. Although certain features related to the openings  14 - 22  and bezel  26  are listed above, it will be appreciated that other features and equivalents thereof associated with the features described above may be included with the instrument panel  10 ,  100 , as desired. 
         [0023]    Referring now to  FIGS. 2 and 3 , an enlarged view of the instrument panel  10 ,  100  is shown according to an embodiment. Referring first to  FIG. 2 , a partially-formed view of the instrument panel  10 ,  100  is shown whereby the partially-formed instrument panel is shown to include a first material  50  that is shaped to provide the opening  12  and the bezel  24 . Referring to  FIG. 3 , a fully-formed instrument panel  10 ,  100  is shown to include a second material  75  that is provided in and extends across the bezel  24  thereby closing-out the opening  12  formed by the first material  50 . 
         [0024]    Referring to  FIG. 4A , the second material  75  is shown extending across the bezel  24  and including one or more pre-weakened portions  77  formed in an outboard side  79  of the second material  75 . As illustrated, the one or more pre-weakened portions  77  are formed proximate a perimeter  32  of the opening  12 . According to an embodiment, as illustrated in  FIGS. 5A-5D , one or more pre-weakened portions  77   a - 77   d  may be formed proximate the perimeter  32  in a square/rectangle shape  77   a  ( FIG. 5A ), a U-shape  77   b  ( FIG. 5B ), an H-shape  77   c  ( FIG. 5C ), or an X-shape  77   d  ( FIG. 5D ). Referring to  FIG. 4A , according to an embodiment, the one or more pre-weakened portions  77  may include a V-shaped notch extending into the outboard side  79  of the second material  75  but not through to an inboard side  81  of the second material  75 . 
         [0025]    Although shown in cross-section in  FIG. 4A , it will be appreciated that the one or more pre-weakened portions  77  may include a continuous V-shaped notch extending in the pattern  77   a - 77   d  proximate that of the perimeter  32  of the opening  12 , or, alternatively, the one or more pre-weakened portions  77  may include a series of interrupted V-shaped notches that form the pattern  77   a - 77   d  proximate the perimeter  32  of the opening  12 . However, it will be appreciated that a continuous V-shape, or, a series of V-shaped interruptions may include any desirable pattern as desired, such as, for example a U-, H-, or X-shape as described above. 
         [0026]    Even further, it will be appreciated that the pre-weakened portion  77  is not limited to a V-shape formed in the outboard side  79  of the second material  75  and that the pre-weakened portion  77  may include any desirable shape, such as, for example, a slit, cut, or notch having any desirable shape. According to an embodiment, the outboard side  79  of the second material  75  may be in-molded, laser-scored, cut, trimmed, or the like to provide the pre-weakened portion  77 . 
         [0027]    Referring to  FIG. 4B , an instrument panel  100  is shown according to an embodiment. Similar to the instrument panel  10  of  FIG. 4A , the instrument panel  100  includes a first material  50  that forms the opening  12  and a second material  75  that extends across the bezel  24  and including one or more pre-weakened portions  77  formed in an outboard side  79  of the second material  75  as described above. In addition, the second material  75  is also shown extending, according to an embodiment, in a substantially perpendicular direction, away from the outboard side  79 , thereby forming a chute portion  83 . As illustrated, the chute portion  83  is formed adjacent a chute portion/support  52  formed by the first material  50 . As illustrated, the chute portion/support  52  extends, according to an embodiment, in a substantially perpendicular direction, away from an outboard side  54  of the first material  50 . 
         [0028]    According to an embodiment, the chute portion/support  52  includes one or more radial openings  56  that extend through the chute support  52  relative an axis, A-A, that extends axially through the opening  12 . The one or more radial openings  56 , which are also shown in  FIG. 4A , may be utilized for any desirable purpose. According to an embodiment, as illustrated in  FIG. 4B , the one or more radial openings  56  formed in the instrument panel  100  may receive a flange  85  that extends, according to an embodiment, in a substantially perpendicular direction, away from the chute portion  83  of the second material  75 . According to an embodiment, the one or more radial openings  56  may function in receiving a fastener (not shown) that fastens the inflatable restraint  11  to the instrument panel  10 . 
         [0029]    As such, because the instrument panel  10 ,  100  includes the second material  75  having one or more pre-weakened portions  77 , the second material  75  provides an inflatable restraint door  34  that permits the inflatable restraint  11  to inflate and pass through the chute portion/support  52  and/or chute portion  83  and out to the inboard side  30  of the instrument panel  10 ,  100 . Accordingly, if the one or more pre-weakened portions  77  is/are formed to include, for example, a U-shape  77   b  ( FIG. 5B ), the door  34  may provide a hinge portion  36 . As shown in  FIGS. 4A and 4B , when the inflatable restraint  11  is deployed, the inflatable restraint door  34  (also shown in phantom), may pivot about the hinge portion  36  according to the pivoting arc, P. 
         [0030]    The first material  50  may include, according to an embodiment, a substantially rigid substrate material, such as, for example, a thermoplastic elastomer, a thermoplastic elastomer polyolefin, a polycarbonate, a polypropylene, an acrylonitrile butadiene styrene (ABS), a polycarbonate acrylonitrile butadiene styrene PC-ABS, a styrene maleic anhydride (SMA), a polyphenylene oxide (PPO), a nylon, a polyester, an acrylic, a polysulfone, or thermoplastic olefin (TPO). According to an embodiment, the first material may include an ABS-PC blend. 
         [0031]    According to an embodiment, the second material  75  is a substantially softer material in comparison to the rigidified characteristic of the first material  50 , and may include any desirable material, such as, for example, a polymer, a synthetic rubber, a thermoplastic elastomer (TPE), a thermoplastic elastomer olefin (TPO), or polycarbonate (PC). According to an embodiment, the second material  75  may include a PC material. According to an embodiment, the second material  75  may be a PC siloxane copolymer resin that offers low temperature ductility (e.g., at approximately −40° C.) in combination with excellent processability and release with properties for shorter mold tool cycles times. According to an embodiment, the second material  75  may be a copolymer resin that is commercially available from General Electric Company of NY, N.Y. and sold under the trade-name LEXAN®. 
         [0032]    According to an embodiment, because an inboard sides  58 ,  81  of the first and second materials  50 ,  75  define the inboard side  30  of the instrument panel  10 ,  100 , the inboard sides  58 ,  81  may include a substantially similar color, appearance, and/or texture to provide an aesthetically-pleasing show- or A-surface that is visually and/or texturally-pleasing for vehicle passengers and/or vehicle enthusiasts. However, it will be appreciated that the inboard side  58 ,  81  of the first and second materials  50 ,  75  may include a different color, appearance, and/or texture quality in comparison with one another. Even further, it will be appreciated that, according to an embodiment, the first and second materials  50 ,  75  may, in combination, provide a substrate layer that receives one or more of a foam layer (not shown) and/or skin layer (not shown) over the inboard side  30  of the instrument panel  10 ,  100 . 
         [0033]    Referring now to  FIGS. 6A-6C  and  7 A- 7 C, a method for manufacturing the instrument panel  10 ,  100  is shown according to an embodiment. According to an embodiment, the first material  50  is attached or otherwise bonded to the second material  75  by using any desirable methodology. 
         [0034]    According to an embodiment, the first and second materials  50 ,  75  are attached at least at a first portion proximate the bezel  24  (see, e.g.  FIG. 4A ). According to an embodiment, the attachment of the first and second materials  50 ,  75  at least proximate the bezel  24  may include, for example, a chemical bond, an adhesive bond, or the like. However, it will be appreciated that the invention is not limited to a chemical bond, an adhesive bond, or the like and that the invention may be practiced utilizing any type of attachment as desired. 
         [0035]    According to an embodiment, the first and second materials  50 ,  75  are attached at least at a first portion proximate the bezel  24  and at least at a second portion proximate the chute portion/support  52  (see, e.g.,  FIG. 4B ). According to an embodiment, the attachment of the first and second materials  50 ,  75  at least proximate the bezel  24  and chute portion/support  52  may include, for example, a chemical bond, an adhesive bond, a mechanical bond, or the like. However, it will be appreciated that the invention is not limited to a chemical bond, an adhesive bond, a mechanical bond, or the like and that the invention may be practiced utilizing any type of attachment as desired. 
         [0036]    According to an embodiment, selection of the first and second materials  50 ,  75  may provide the attachment as described above when the first and second materials  50 ,  75  are provided in a mold tool  200  ( FIGS. 6A-6C ),  300  ( FIGS. 7A-7C ). According to an embodiment, the attachment of the first and second materials  50 ,  75  is provided by way of multi-shot molding/over-molding process. Because the illustrated embodiment includes a first and second material  50 ,  75 , the multi-shot molding process may be referred to as a two-shot molding process. 
         [0037]    Referring first to  FIGS. 6A-6C , the mold tool  200  includes first and second mold halves  202   a ,  202   b  and one or more mold core components  204   a ,  204   b  that form the instrument panel  10  of  FIG. 4A . Although two mold core components  204   a ,  204   b  are shown, it will be appreciated that the mold tool  200  may include any desirable number of mold core components that shift and change positioning to re-define a cavity volume  206   a  ( FIG. 6A ),  206   b  ( FIG. 6B ) of the mold tool  200  before, during, or after the mold halves  202   a ,  202   b  are moved to place the mold tool  200  in a closed position. 
         [0038]    First, as seen in  FIG. 6A , the first and second mold halves  202   a ,  202   b  are moved adjacent one another to place the mold tool  200  in a closed position As illustrated, the first mold half  202   a  includes a surface  203   a  that substantially defines an outboard side  58  of the first material  50 . Correspondingly, the second mold half  202   b  includes a surface  203   b  that substantially defines an inboard side  54  of the first material  50   
         [0039]    Referring still to  FIG. 6A , the first and second core components  204   a ,  204   b  are shown in a first position prior to depositing a shot of the first material  50 . As illustrated, the mold halves  202   a ,  202   b  and first and second core components  204   a ,  204   b  define the first cavity volume  206   a . The first cavity volume  206   a , according to an embodiment, is substantially equal to a volume of a first shot of a first material  50  that is used to fill the first cavity volume  206   a  to form the rigid substrate of the instrument panel  10  including the plurality of openings  12 - 22 , the one or more recessed bezels  24 ,  26 , chute portion/support  52 , and one or more radial openings  56 . As illustrated, the second core component  204   b  is provided to form the one or more radial openings  56  extending through the chute portion/support  52 . 
         [0040]    Referring now to  FIG. 6B , once the first material  50  substantially cures to partially or completely harden in the first cavity volume  206   a , or, alternatively, when the first material  50  is still in a reactive state (i.e. the first material  50  is tacky or not substantially hardened), the first core component  204   a  is retracted to expose the recessed bezel  24  that is provided by the first material  50 . As such, the recessed bezel  24  and portions of the surfaces  203   a ,  203   b  of the mold halves  202   a ,  202   b  define the second cavity volume  206   b  that is substantially equal to a volume of a second shot of a second material  75 . As illustrated, the surface  203   b  also includes a V-shaped ridge  205  that may be utilized to in-mold the one or more pre-weakened portions  77  when the shot of the second material  75  is deposited. 
         [0041]    As seen in  FIG. 6C , the shot of second material  75  is deposited and fills the second cavity volume  206   b  to provide the inflatable restraint door  34 . According to an embodiment, the shot of second material  75  attaches to a localized portion  60  of the inboard side  58  of the first material  50 , particularly within and filling the recessed bezel  24 . When the shot of the second material  75  attaches to a localized portion  60  of the shot of first material  50 , the instrument panel  10  is formed such that the shot of the second material  75  closes-out the opening  12  defined by the chute portion/support  52 . As such, the shot of the second material  75  is provided over the shot of the first material  50  in a localized manner such that an inboard surface  30  of the instrument panel  10  is provided to define a seamless inflatable restraint door  34 . 
         [0042]    Referring now to  FIGS. 7A-7C , the mold tool  300  includes first and second mold halves  302   a ,  302   b  and one more mold core components  304   a ,  304   b  that form the instrument panel  100  of  FIG. 4B . The mold halves  302   a ,  302   b  and mold core components  304   a ,  304   b  function substantially similarly to the first and second mold halves  202   a ,  202   b  and the one or more mold core components  204   a ,  204   b , but, however, include variations to accommodate the second shot of second material  75  that defines the chute portion  83  and flange  85  that extends from the chute portion  83 . 
         [0043]    Referring to  FIG. 7A , the first and second core components  304   a ,  304   b  are shown in a first position prior to the depositing of the shot of the first material  50 . As illustrated, the mold halves  302   a ,  302   b  and first and second core components  304   a ,  304   b  define the first cavity volume  306   a . The first cavity volume  306   a , according to an embodiment, is substantially equal to a volume of a first shot of a first material  50  that is used to fill the first cavity volume  306   a  to form the rigid substrate of the instrument panel  100  including the plurality of openings  12 - 22 , the one or more recessed bezels  24 ,  26 , chute portion/support  52 , and one or more radial openings  56 . As illustrated, the second core component  304   b  is provided to form the one or more radial openings  56  extending through the chute portion/support  52 . 
         [0044]    Referring now to  FIGS. 7A and 7B , once the first material  75  substantially cures to partially or completely harden in the first cavity volume  306   a , the first core component  304   a  is retracted to expose the recessed bezel  24  and an inner periphery wall  62  of chute portion/support  52  that is provided by the first material  50 . Then, the second core component  304   b  is retracted according to the direction of the arrow, C, to expose the one or more radial openings  56  ( FIG. 7C ). As such, the recessed bezel  24 , the one or more radial openings  56 , inner periphery wall  62 , portions of the surfaces  303   a ,  303   b  of the mold halves  302   a ,  302   b , and an end  307  of the second mold core  304   b  defines the second cavity volume  306   b  that is substantially equal to a volume of a second shot of a second material  75 . As illustrated, the surface  303   b  also includes a V-shaped ridge  305  that may be utilized to in-mold the one or more pre-weakened portions  77  in the shot of the second material  75 . 
         [0045]    As seen in  FIG. 7C , the shot of second material  75  that fills the second cavity volume  306   b  provides the inflatable restraint door  34 . According to an embodiment, the shot of second material  75  attaches to the localized portion  60  of the inboard side  58  of the first material  50 , particularly within and filling the recessed bezel  24 . Additionally, because the shot of second material  75  fills the one or more radial openings  56 , the shot of the second material  75  also attaches to the chute portion/support  52 . Thus, when the shot of the second material  75  attaches to the shot of the first material  50  as described above, the instrument panel  100  is formed and the shot of the second material  75  closes-out the opening  12  defined by the chute portion/support  52 . As such, the shot of the second material  75  is provided over the shot of the first material  50  in a localized manner such that an inboard surface  30  of the instrument panel  10  is provided and defines a seamless inflatable restraint door  34 . 
         [0046]    It will be appreciated that the inventive multi-shot method for manufacturing the instrument panel  10 ,  100  is not limited to the mold tools  200 ,  300 . For example, although the subject invention involves the use of a mold tool  200 ,  300  that includes a cavity volume  206   a ,  206   b ,  306   a ,  306   b , the invention is not limited by the number of volumes  206   a ,  206   b ,  306   a ,  306   b  in which the mold tool  200 ,  300  can be altered, and that the invention can be practiced with a cavity volume  206   a ,  206   b ,  306   a ,  306   b  that may be altered into any desirable number of volumes needed to form the component. 
         [0047]    In addition, there are a variety of techniques, in addition to movable mold cores  204   a ,  204   b ,  304   a ,  304   b , that permit altering of the cavity volume  206   a ,  206   b ,  306   a ,  306   b  from a first volume to another different volume. Such techniques may include, for example, the use of a moveable slide, transfer molding, or even the use of a rotating platen. However, it will be appreciated that any desirable technique is appropriate and that the scope of the invention is not limited to a technique for altering the shape or size of the cavity volume  206   a ,  206   b ,  306   a ,  306   b  from a first volume to another, different volume. 
         [0048]    The present invention has been described with reference to certain exemplary embodiments thereof. However, it will be readily apparent to those skilled in the art that it is possible to embody the invention in specific forms other than those of the exemplary embodiments described above. This may be done without departing from the spirit of the invention. The exemplary embodiments are merely illustrative and should not be considered restrictive in any way. The scope of the invention is defined by the appended claims and their equivalents, rather than by the preceding description.