Abstract:
An insert is assembled to a base interior part at either an edge or a corner of the part that is later wrapped with a cut and sewn jacket cover. The assembly comprises a substrate, an insert and a cover. The substrate has a base edge and the insert has a contour defining edge attached to the substrate with the contour defining edge aligned with the base edge. The cover is wrapped over the insert and the substrate to provide a wrapped edge that covers over the contour defining edge. A method of manufacturing a covered interior part of a vehicle comprises securing an insert having a contour defining edge to the interior panel and wrapping the insert and the interior panel with a cover.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a division of U.S. application Ser. No. 14/536,744 filed Nov. 10, 2014, the disclosure of which is hereby incorporated in its entirety by reference herein. 
     
    
     TECHNICAL FIELD 
       [0002]    This disclosure relates to parts that are wrapped with a decorative covering material that are provided with sharp corners or edges. 
       BACKGROUND 
       [0003]    Vehicles such as automobiles, trucks, boats, airplanes and the like may offer interior parts that are provided with surfaces that are wrapped with covering materials, such as leather or other premium materials. For example, interior panels such as door inner panels, instrument panels and interior trim pieces may be covered with hand-wrapped genuine leather covers. The covers may be cut and sewn jackets that are wrapped onto metal or plastic base level interior panels that are sold without leather wrapping. 
         [0004]    Base level interior panels (lower trim level interior panels that have less features and may be offered at a lower price) may be prepared for wrapping by removing an outer surface area to accommodate the increased thickness of the finished wrapped assembly. Interference with adjacent parts caused by the leather wrap may be eliminated by milling critical areas of the base level interior part. For example, the surface of a base level instrument panel may be milled in the area of an air vent insert that is assembled to an opening defined by the leather wrapped part as a plug-in part. 
         [0005]    Wrapping a base level interior part with leather tends to create a wrapped part that has edges and corners that are more rounded (have a larger corner radius) than the base level interior parts. The edges of such parts must match the edges of other parts such as the plug-in air vents described above that may have square edges that are designed to be received into openings in the base level interior parts. Undesirable wide gaps may be defined between edges and mating parts (for example, between assembled parts and the leather wrapped parts or between leather wrapped parts and doors or other closure panels) if the edges are rounded when the parts are wrapped with cut and sewn jackets. 
         [0006]    This disclosure is directed to solving the above problems and other problems as summarized below. 
       SUMMARY 
       [0007]    An insert that defines a sharp edge is proposed to be assembled to a base interior part at either an edge or a corner of the part that is later wrapped with a cut and sewn jacket cover. The insert can be used for edges or corners where the tightness of the wrap or interference with an adjacent part is a concern. The sharp edge of the insert is positioned at an edge or corner where sharpness of the interior part is important. The insert may be attached by fastening mechanisms such as tacks, staples, or an adhesive. The fastening mechanisms may be molded into the insert. The base level interior part may be machined (milled or bored) or molded with locating features designed to receive the insert. 
         [0008]    The corners or edges formed on the insert may be sharp corners formed by a raised rib or may be provided with a ball end or cylindrical edge. The height of the raised rib, ball end or cylindrical edge may be determined based upon the suppleness of the wrapping material. 
         [0009]    The insert may be made from a relatively rigid plastic but can be made from ethylene propylene diene monomer (EPDM) rubber or another elastomer or polymer that has the appropriate hardness to define the corner area after being wrapped with a covering material. To achieve the desired balance of suppleness and rigidity at the edge or corner, other materials such as a closed cell foam, a two-shot injection molded material, or the like may be used to form the insert. 
         [0010]    According to one aspect of this disclosure, an assembly is provided that comprises a substrate, an insert and a cover. The substrate has a base edge and the insert has a contour defining edge attached to the substrate with the contour defining edge aligned with the base edge. The cover is wrapped over the insert and the substrate to provide a wrapped edge that covers over the contour defining edge. 
         [0011]    According to other aspects of this disclosure, the insert may have an inner surface attached to the substrate and an outer surface oriented to provide a facing over the substrate. The contour defining edge has an edge radius that is smaller than a nominal radius of the base edge. The contour defining edge extends outwardly from the outer surface (or “A” side) away from the inner surface (or “B” side). 
         [0012]    The insert may have a first leg that is attached to a facing wall of the substrate and a second leg that is attached to a recess defining wall of the substrate that extends into the substrate from the facing wall. The contour defining edge is formed at the intersection of the first wall and the second wall. Alternatively, the insert may have a first leg that is attached to a facing wall of the substrate and a second leg that is attached to a recess defining wall of the substrate that extends into the substrate from the facing wall. The contour defining edge is provided on the first leg adjacent the intersection of the first wall and the second wall to extend from the outer surface away from the inner surface. 
         [0013]    The base edge may extend about an external corner of the substrate with the contour defining edge of the insert paralleling the base edge. The insert may include a ball-shaped end at the external insert corner. 
         [0014]    The assembly may further comprise means for attaching the insert to the substrate. The means for attaching the insert may be an adhesive applied between the insert and the substrate for securing the insert to the substrate. Alternatively, the attachment means may be a mechanical fastener connecting the insert to the substrate. 
         [0015]    Another aspect of this disclosure relates to a method of manufacturing a covered part for a vehicle. The method includes the steps of selecting an interior panel that includes an edge, securing an insert having a contour defining edge to the interior panel with the contour defining edge spaced from and parallel to the edge of the substrate, and wrapping the insert and the substrate with a cover that defines a corner over the contour defining edge. 
         [0016]    According to other aspects of the method, the method may include the further step of milling the interior panel in an area adjacent the edge to provide clearance relative to an adjacent part to the covered part. Alternatively, the method may include the step of molding a recessed area on the interior panel in an area adjacent the edge to provide clearance relative to apart that is adjacent to the covered part, and then assembling the insert onto the recessed area. 
         [0017]    The method may further comprise applying an adhesive between the insert and the interior panel, and securing the insert to the substrate with the adhesive. Alternatively, the method may include the step of fastening the insert to the interior panel with a mechanical fastener to connect the insert to the interior panel. 
         [0018]    The above aspects of this disclosure and other aspects will be described in greater detail below with reference to the attached drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0019]      FIG. 1  is a fragmentary perspective view of a portion of an interior panel that has a covering material wrapped over a contour defining insert with part of the covering material partially removed for visibility. 
           [0020]      FIG. 2  is an exploded perspective view of an assembly made according to this disclosure. 
           [0021]      FIG. 3  is a fragmentary cross-sectional view taken along the line  3 - 3  in  FIG. 1  of one embodiment of an assembly made according to this disclosure. 
           [0022]      FIG. 4  is a fragmentary cross-sectional view similar to  FIG. 3  of another embodiment of an assembly made according to this disclosure. 
           [0023]      FIG. 5  is a fragmentary cross-sectional view similar to  FIG. 3  of another embodiment of an assembly made according to this disclosure. 
           [0024]      FIG. 6  is a fragmentary cross-sectional view similar to  FIG. 3  of another embodiment of an assembly made according to this disclosure. 
           [0025]      FIG. 7  is a fragmentary cross-sectional view similar to  FIG. 3  of another embodiment of an assembly made according to this disclosure. 
           [0026]      FIG. 8  is a fragmentary cross-sectional view taken along the line  8 - 8  in  FIG. 1  of another embodiment of an assembly made according to this disclosure. 
           [0027]      FIG. 9  is a fragmentary perspective view of an insert that defines a rounded corner at the apex of three sides of the insert. 
           [0028]      FIG. 10  is a fragmentary perspective view of another insert that defines a rounded corner at the apex of three sides of the insert and a cylindrical edge at the intersection of two of the sides. 
       
    
    
     DETAILED DESCRIPTION 
       [0029]    The illustrated embodiments are disclosed with reference to the drawings. However, it is to be understood that the disclosed embodiments are intended to be merely examples that may be embodied in various and alternative forms. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. The specific structural and functional details disclosed are not to be interpreted as limiting, but as a representative basis for teaching one skilled in the art how to practice the disclosed concepts. 
         [0030]    Referring to  FIG. 1 , a wrapped interior part assembly  10 , or “assembly”, is illustrated that includes a substrate part  12  on which an overlaid insert  14  is assembled prior to covering the assembly with a cover  16 . The substrate part  12  may be an interior part for a car, such as a dashboard, interior door panel, console, glove box door, seat, or the like. 
         [0031]    The insert  14  is assembled to the substrate part  12  near a base edge  18  of the substrate part  12 . The insert  14  includes a contour defining edge  20  that is positioned in alignment with the base edge  18 . The contour defining edge  20  is outboard of the base edge  18  and provides a sharp feature line when the cover  16  is wrapped over the assembly and insert and substrate  12 . 
         [0032]    While not necessary in every assembly  10 , a spacer  24  may be assembled between the substrate part  12  and overlaid insert  14  to provide a cushioned feel that emphasizes the suppleness of a leather cover  16 . The spacer  24  may be a foam layer or sheet. The spacer  24 , as shown in  FIG. 1 , extends across the substrate part  12  and partially over the overlaid insert  14 , but does not extend across the contour defining edge  20 . In several of the embodiments to be described below, the spacer  24  extends over the contour defining edge  20 . 
         [0033]    The substrate part  12  includes a facing wall  26 , or outer surface, of the substrate part  12 . In many applications, the substrate part may be a vinyl part that includes the Class A surface of the part. Higher level trim is provided by wrapping the substrate part  12  with a premium covering material, such as leather. While leather is the most common premium covering material, the cover may also be made of other premium fabrics or materials. In many instances, the substrate part  12  is milled or machined to provide clearance for the wrapped cover  16  in areas where the assembly  10  may interfere with assembled parts or adjacent vehicle components. The substrate part  12  may also include a side wall  28  that extends inwardly from the facing wall  26 . The side wall  28  may also require machining to provide clearance for the addition of the cover  16  to the assembly  10 . 
         [0034]    A recess defining wall  30  may be provided that extends inwardly relative to the facing wall  26 . The recess defining wall  30  defines a recess, or opening, in the substrate part  12  that may be used to insert an attachment  32 , such as an air vent, trim piece, or the like. Alternatively, the wall  30  may be adapted to receive a different part or may be aligned with another plug-in part. The attachment  32  may be a snap-in part, adhesively secured part, or otherwise fastened to the substrate part  12  after the cover  16  is attached to the assembly  10 . The overlaid insert  14  has an inner surface  34  that is placed in a face-to-face relationship on the facing wall  26  of the substrate part  12 . The overlaid insert  14  also includes an outer surface  36  that faces away from the inner surface  34 . The outer surface  36  is preferably tapered toward the substrate part  12  facing wall  26  to reduce the possibility that the insert may be discernable or detectable after the cover  16  is attached. 
         [0035]    Referring to  FIG. 2 , the assembly  10  is shown as an exploded perspective view of a small segment of the assembly  10 . The assembly  10  includes the substrate part  12  that includes the base edge  18 . The substrate  12  includes a facing wall  26  and a side wall  28  that are covered by the cover  16  when it is wrapped over the assembly  10 . The insert  14  provides the contour defining edge  20  when it is assembled onto the substrate  12  with the contour defining edge  20  generally following the base edge  18 . The inner surface  34  of the insert  14  is attached to the facing wall  26  of the substrate  12 . The outer surface  36  of the insert  14  faces in generally the same direction as the facing wall  26  of the substrate  12 . The outer surface  36  tapers toward the facing wall  26  of the substrate part  12 . The spacer  24  is shown disposed between the outer surface  36  of the insert  14  and the cover  16 . 
         [0036]      FIGS. 3-8  illustrate several different embodiments of the assembly  10  that include several different types of inserts. Referring to  FIG. 3 , an insert  14  that is like the insert shown in  FIGS. 1 and 2  is shown assembled to a substrate  12 . The substrate  12  defines a base edge  18  while the insert  14  includes the contour defining edge  20 . The spacer  24  may extend across the outer surface  36  of the insert  14  and over the contour defining edge  20  to also cover the side wall  28  of the assembly  10 . A snap-in fastener  38  may be provided as an integrally molded part of the insert  14  to secure the insert  14  to the substrate  12 . Alternatively, the snap-in fastener may be a screw or separate snap-in fastener  38  as shown below and described with reference to  FIG. 4 . 
         [0037]    Referring to  FIG. 4 , the insert  14  is shown to be assembled into an outer surface recess  40  that is formed in the facing wall  26  of the substrate part  12 . A screw  42  is shown that is used to secure the insert  14  to the substrate part  12 . A spacer  24  is assembled over the insert  14  and the facing wall  26  of the substrate  12 . The recess  40  locates the insert on the substrate  12 . The recess  40  may be formed by machining or milling the surface of the substrate  12  to remove material from the substrate  12 . Alternatively, the substrate part  12  may be molded to define the recess  40 . The substrate  12  may be bored to form a hole or opening to receive the screw  42  or the snap-in fastener  38  (shown in  FIG. 3 ). 
         [0038]    A cylindrical area  46  may be provided at the contour defining edge  20  to provide a more durable contour defining edge  20  that provides a small radius contour defining edge  20  instead of a sharp point, as shown in  FIGS. 1-3 . 
         [0039]    Referring to  FIG. 5 , a corner insert  48  is shown to be installed in a recess  50 . The corner insert  48  may be secured to the substrate  12  by an adhesive  52 . An inverted V-shaped protrusion  56  is provided on the corner insert  48  at a location that is recessed laterally relative to the side wall  28 . The inverted V-shaped protrusion  56  is provided on a top surface  58  of the corner insert  48 . A spacer  24  is assembled over the top surface  58  and the substrate  12  before it is covered by the cover  16 . 
         [0040]    Referring to  FIG. 6 , another embodiment of a corner insert  48  is shown that is secured by an adhesive  52  to the substrate  12 . The corner insert  48  includes an inverted V-shaped protrusion  56  that is located at a corner  60  of the corner insert  48 . The V-shaped protrusion  56  extends diagonally relative to the facing wall  26  and side wall  28  of the corner insert  48 . The spacer  24  is assembled over the corner insert  48  and the substrate  12 , but does not extend over the V-shaped protrusion  56 . The cover  16  is assembled over the insert  48 , substrate  12  and spacer  24 . 
         [0041]    Referring to  FIG. 7 , another corner insert  48  is illustrated that is assembled over the base edge  18  of the substrate  12 . The inverted V-shaped protrusion  56  extends from a side portion  62  of the insert  48 . The insert  48  is assembled into a recess  50  that is formed either by machining or molding in the substrate  12  as previously described. The spacer fabric  24  is shown to be assembled over the facing wall  26  and side wall  28 . The spacer  24  also extends over the protrusion  56  and the insert  48 . 
         [0042]    Referring to  FIG. 8 , this view is taken as a cross-sectional view in  FIG. 1  to show the application of the corner insert  48  in a recess defining wall  30  that is adapted to receive an attachment  32 , such as an air vent or trim piece. The corner insert  48  is assembled to the substrate  12  to provide a sharp corner in the area where the attachment  32  is adjacent to the substrate  12 . The insert  48 , shown in  FIG. 8 , does not include a protrusion, but is L-shaped and extends along the edge of the substrate with the base edge  18  and substrate  12  being inboard of the contour defining edge  20 . The cover  16  and the foam spacer  24  extend across the facing wall  26 , the corner insert  48  and the recess defining wall  30 . 
         [0043]    Referring to  FIG. 9 , a ball-shaped rounded corner  64  is illustrated that may be provided on the insert  14  shown in  FIGS. 1-4  or on a corner insert  48  as shown in  FIGS. 5-8 . The ball-shaped rounded corner  64  provides a slightly rounded end of small radius. The ball-shaped rounded corner  64  reduces the sharpness of the finished corner and reduces any tendency to pierce the cover  16 . 
         [0044]    Referring to  FIG. 10 , another alternative embodiment of a corner insert  48  is shown that includes a ball-shaped rounded corner  64  that is provided where three faces intersect on the insert. Cylindrical edges  46  are provided on the edges that lead to the ball-shaped rounded corner  64 . The cylindrical edges  46  provide a rounded linear edge between two faces of the insert  48 . The rounded corner  64  or cylindrical edge  46  provide a smaller radius surface over which the cover  16  is wrapped, as described with reference to  FIGS. 1-8  above. 
         [0045]    While the embodiment of  FIGS. 1-4  is shown with the triangular protrusion  22  extending upwardly relative to the substrate part  12 , it should be understood that the triangular protrusion  22  may be oriented in a diagonal direction similar to the protrusion  56  shown in  FIG. 6  or may extend over the side wall  28  of the substrate  12  similar to the corner insert  48  shown in  FIG. 7 . 
         [0046]    The structural elements shown and described with reference to the drawings may be modified or combined with other structural features shown in the other figures of the drawings. The embodiments described above are specific examples that do not describe all possible forms of the disclosure. The features of the illustrated embodiments may be combined to form further embodiments of the disclosed concepts. The words used in the specification are words of description rather than limitation. The scope of the following claims is broader than the specifically disclosed embodiments and also includes modifications of the illustrated embodiments.