Abstract:
A method of producing tight bezel fits between automotive interior panels and their mating subcomponents. The method includes forming at laminate preform, injection molding a substrate layer behind the laminate preform to form a molded automotive interior panel, and forming an opening in the molded automotive interior panel. The method further includes post embossing the molded automotive interior panel adjacent a perimeter of the opening to produce an embossed interface between the molded automotive interior panel and a mating subcomponent installed in the opening, thereby producing a tight bezel fit between the molded automotive interior panel and the mating subcomponent installed in the opening. Alternatively, the method includes utilizing a vacuum wrapped automotive interior panel with the embossing step described above. The invention also provides for an automotive interior panel including a tight bezel fit between the panel and mating subcomponents, formed by the aforementioned methods.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application is a divisional of U.S. application Ser. No. 11/041,289, filed Jan. 25, 2005, now U.S. Pat. No. 7,217,387, which, in turn, claims the benefit of U.S. Provisional Patent Application Nos. 60/538,477 filed Jan. 26, 2004 and 60/563,461 filed Apr. 20, 2004, the disclosures of which are each hereby incorporated by reference in their entirety. 

   BACKGROUND OF INVENTION 
   a. Field of Invention 
   The invention relates generally to automotive component manufacture and installation, and, more particularly to a method for producing tight bezel fits between automotive instrument panels and their surface mating subcomponents, and further to the same method as applied to automotive door inner liners (the interior show surface of an automotive door) and other structures requiring similar construction. 
   b. Description of Related Art 
   In the art, there presently exist a variety of methods, such as mold behind or vacuum wrapped technology, for manufacturing vehicle instrument panels and similar structures. Mold behind technology generally involves a single-step advanced injection-molding process that integrates cover materials to form the structure of automotive instrument panels, doors and the like. Vacuum wrapped technology, as discussed in detail in applicant&#39;s co-pending U.S. Application titled “Thermoforming of Ink Jet Printed Media for the Decoration of Soft Grained Automotive Interior Components,” the disclosure of which is incorporated by reference, typically involves the wrapping of a substrate with heated thermoplastic (TP) bi-laminate sheet (most commonly consisting of a compact thermoplastic layer and a soft foam thermoplastic layer) for forming an automotive interior panel component, and evacuating the air from between the substrate and the sheet, such that atmospheric pressure pushes the sheet onto the mold, thereby stretching the sheet as required to form in three dimensions. An adhesive either on the substrate, or the bi-laminate sheet secures the wrapped layers to the structural substrate. 
   Regardless of whether mold behind or vacuum wrapped technology is employed, instrument panels constructed from such known technology have thus far been limited to large (i.e. &gt;2.5 mm) radii and loose fit conditions. For example, referring to  FIGS. 1-3 , an instrument panel  10  including an object  12  (i.e. a side window defroster) mounted in gap  14  is illustrated. The geometry around instrument panel openings adjacent the edge mating surfaces of object  12  and instrument panel  10  at locations  16 ,  18  and  20 , on injection mold behind foam laminate constructions and vacuum wrapped technology, has been thus far been severely limited (i.e. mating surface radii are typically &gt;2.5 mm), thus greatly affecting fit and finish with the subcomponents. While such construction is acceptable for relatively inexpensive automobiles, for higher-end automobiles, a tighter fit construction (i.e. a mating surface radii between 0-0.5 mm) is required. Such fit requirements in higher-end automobiles have thus far required complex processes which add to the overall cost of the automobile due to the increased labor and manufacturing costs. 
   It would therefore be of benefit to provide an instrument panel construction method which achieves the fit constraints of higher-end automobiles, without significantly adding to the labor and manufacturing costs for such constructions in lower-end automobiles. It would also be of benefit to provide a construction method which is repeatable and readily usable for a variety of automobiles, and which produces an end-product which meets automotive safety and reliability criteria. 
   SUMMARY OF INVENTION 
   The invention solves the problems and overcomes the drawbacks and deficiencies of prior art mold behind and vacuum wrapped technology construction methods by providing a method for producing high quality instrument panels and other components having a tight fit construction (i.e. a mating surface radii between 0-0.5 mm) for installation of subcomponents, for example, side window defrosters, as well as air conditioning registers, speakers, windshield defrosters, navigation unit openings and the like. 
   The present invention thus provides a method of producing tight bezel fits between automotive interior panels and their mating subcomponents. The method includes forming at laminate preform (formed by vacuum forming), injection molding a substrate layer behind the laminate preform to form a molded automotive interior panel, and forming an opening in the molded automotive interior panel. The method further includes post (meaning after injection molding) embossing the molded automotive interior panel adjacent a perimeter of the opening to produce an embossed interface between the molded automotive interior panel and a mating subcomponent installed in the opening, thereby producing a tight bezel fit between the molded automotive interior panel and the mating subcomponent installed in the opening. 
   For the method described above, the laminate preform may be a multi-layer laminate preform, and include a skin layer and a foam layer. The molded automotive interior panel may include a sloped section adjacent the embossed interface to permit an outer surface of the mating subcomponent to lay flush relative to an outer surface of the molded automotive interior panel. The opening may be formed by punching or cutting, and the embossing tool may be a heated tool or an ultra-sonic tool. The embossing step provides an interface radius of less than approximately 0.5 mm. Further, for the embossing step, a gap between an edge of the embossed interface and the mating subcomponent installed in the opening may be less than approximately 0.125 mm. 
   For an alternative embodiment, the present invention provides a method of producing tight bezel fits between automotive interior panels and their mating subcomponents. The method includes vacuum wrapping over a substrate layer to form a vacuum wrapped automotive interior panel, and forming an opening in the vacuum wrapped automotive interior panel (thus producing a standard vacuum wrapped panel). The method further includes post (this being after the vacuum wrapping operation) embossing the vacuum wrapped automotive interior panel adjacent a perimeter of the opening to produce an embossed interface between the vacuum wrapped automotive interior panel and a mating subcomponent (examples would include air conditioning registers, side window defroster registers, speaker openings and grab handles) installed in the opening, thereby producing a tight bezel fit between the vacuum wrapped automotive interior panel and the mating subcomponent installed in the opening. 
   For the method described above, a wrap used for the vacuum wrapping may be a multi-layer laminate preform, and include a skin layer and a foam layer. The vacuum wrapped automotive interior panel may include a sloped section adjacent the embossed interface to permit an outer surface of the mating subcomponent to lay flush relative to an outer surface of the vacuum wrapped automotive interior panel (in particular it permits the desirable wedged bezel profile for its stiffness, while still allowing the component to lay flush with the panel surface). The opening may be formed by punching or cutting, and the embossing tool may be a heated tool or an ultra-sonic tool. The embossing step provides an interface radius of less than approximately 0.5 mm. Further, for the embossing step, a gap between an edge of the embossed interface and the mating subcomponent installed in the opening may be less than approximately 0.125 mm. 
   The invention yet further provides an automotive interior panel formed by injection molding or vacuum wrapping and including a tight bezel fit between the interior panel and mating subcomponents. The panel includes an opening formed in the interior panel, and an embossed section adjacent a perimeter of the opening defining an embossed interface between the interior panel and a mating subcomponent installed in the opening, such that when the mating subcomponent is installed in the opening, the interior panel includes a tight bezel fit between the panel and the mating subcomponent. 
   For the automotive interior panel described above, the panel may include a sloped section adjacent the embossed interface to permit an outer surface of the mating subcomponent to lay flush relative to an outer surface of the automotive interior panel. An interface radius adjacent the embossed interface may be less than approximately 0.5 mm, and a gap between an edge of the embossed interface and the mating subcomponent installed in the opening may be less than approximately 0.125 mm. 
   Additional features, advantages, and embodiments of the invention may be set forth or apparent from consideration of the following detailed description, drawings, and claims. Moreover, it is to be understood that both the foregoing summary of the invention and the following detailed description are exemplary and intended to provide further explanation without limiting the scope of the invention as claimed. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate preferred embodiments of the invention and together with the detail description serve to explain the principles of the invention. In the drawings: 
       FIG. 1  is a photograph of an automobile instrument panel illustrative of the large radii visible in mating components (i.e. side interior and window defrosters) installed using conventional technology, including a comparative side window defroster installed on the instrument panel for a section thereof manufactured using the embossed manufacturing method according to the present invention; 
       FIG. 2  is a view illustrating existing mold behind technology fit condition; 
       FIGS. 3A-3C  are illustrative views of component interfaces with a main panel surface using conventional vacuum wrapping manufacturing procedures; 
       FIG. 4  is an illustrative view of a manufacturing stage for a first embodiment of the embossed manufacturing method according to the present invention, illustrating tri-laminate, and in alternative forms bi-laminate (sandwiched skin and foam, without the backing ply) preforms or expanded (single layer sheets with a non-porous surface and bubbles creating a foam within) preforms being used in otherwise the same fashion; 
       FIG. 5  is an illustrative view of a manufacturing stage for the first embodiment of the embossed manufacturing method according to the present invention, illustrating mold behind manufacturing in the injection tool; 
       FIG. 6  is an illustrative view of a manufacturing stage for the first embodiment of the embossed manufacturing method according to the present invention, illustrating tri-laminate, and in alternative forms bi-laminate (sandwiched skin and foam, without the backing ply) preforms or expanded (single layer sheets with a non-porous surface and bubbles creating a foam within) preforms under injection pressure; 
       FIG. 7  is an illustrative view of a manufacturing stage for the first embodiment of the embossed manufacturing method according to the present invention, illustrating foam rebound; 
       FIG. 8  is an illustrative view of a manufacturing stage for the first embodiment of the embossed manufacturing method according to the present invention, illustrating the punching of an opening; 
       FIG. 9  is an illustrative view of a manufacturing stage for the first embodiment of the embossed manufacturing method according to the present invention, illustrating embossing; 
       FIG. 10  is an illustrative view of a manufacturing stage for the first embodiment of the embossed manufacturing method according to the present invention, illustrating the resulting construction as embossed and punched; 
       FIG. 11  is an illustrative view of a manufacturing stage for the first embodiment of the embossed manufacturing method according to the present invention, illustrating installation of an object, such as a side window defroster, in the opening; 
       FIG. 12  is an illustrative view of a manufacturing stage for the first embodiment of the embossed manufacturing method according to the present invention, illustrating an enlarged view of the area of contact between the object and the panel edge; and 
       FIG. 13  is an illustrative view of a component interface with a main panel surface using the first and second embodiments of the embossed manufacturing method according to the present invention; 
       FIG. 14  is another illustrative view of a component interface with a main panel surface using the first and second embodiments of the embossed manufacturing method according to the present invention; 
       FIG. 15  is another illustrative view of a component interface with a main panel surface using the first and second embodiments of the embossed manufacturing method according to the present invention; 
       FIGS. 16A-16C  are illustrative views of a component interface with a main panel surface using the first and second embodiments of the embossed manufacturing method according to the present invention, with  FIGS. 16B and 16C  illustrating enlarged views of the interface; 
       FIG. 17  is an illustrative view of a manufacturing stage for the second embodiment of the embossed manufacturing method according to the present invention, illustrating an injection molded foundation which is vacuum wrapped with a bi-laminate (sandwiched skin and foam) preform; 
       FIG. 18  is an illustrative view of a manufacturing stage for the second embodiment of the embossed manufacturing method according to the present invention, illustrating the injection molded foundation vacuum wrapped with a bi-laminate preform; 
       FIG. 19  is an illustrative view of a manufacturing stage for the second embodiment of the embossed manufacturing method according to the present invention, illustrating the punching of an opening; 
       FIG. 20  is an illustrative view of a manufacturing stage for the second embodiment of the embossed manufacturing method according to the present invention, illustrating embossing; and 
       FIG. 21  is an illustrative view of a manufacturing stage for the second embodiment of the embossed manufacturing method according to the present invention, illustrating the resulting construction as embossed and punched. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
   Referring now to the drawings wherein like reference numerals designate corresponding parts throughout the several views,  FIGS. 4-9  and  17 - 21  illustrate the manufacturing stages for producing an embossed opening according to first and second embodiments of the present invention (hereinafter generally referred to as ‘embossed manufacturing method’), and  FIGS. 10-16  illustrate exemplary features of an instrument panel constructed by means of the first and second embodiments of the embossed manufacturing methods of the present invention. 
   Referring to  FIGS. 4-7 , the first embodiment of the embossed manufacturing method according to the present invention may use a bi-laminate or tri-laminate preform (illustrated in  FIG. 4 ), or sheet construction. As shown in  FIG. 4 , the first step in the embossed manufacturing method, which employs the mold behind construction methodology, may include the use of a tri-laminate preform  22  including a top T.P.O. skin layer  24 , a bottom backing layer  26 , and a foam layer  28  sandwiched between layers  24 ,  26 . Layers  24 ,  26  and  28  may have an exemplary thickness of 0.45 mm, 0.25 mm and 0.9 mm, respectively. For the construction illustrated in  FIG. 4 , the layers may not include any defined features to betray preform mislocation and foam rebound errors, and the slope angle minimizes bezel edge thinning. 
   As shown in  FIG. 5 , the exemplary tri-laminate preform may be placed in an injection tool cavity  30  including cavity top and bottom surfaces  32 ,  34 , and include a bulge detail  36  which does not match the preform contour. Referring next to  FIG. 6 , under injection pressure in cavity  30 , tri-laminate preform  22  and substrate  40  are compressed, and the bulge is formed in polypropylene (PP) layer  36 . As shown in  FIG. 7 , after injection, foam layer  28  rebounds, and structural layer  38  including substrate  40  and tri-laminate layer  42  is formed. 
   Referring next to  FIG. 8 , the next step in the embossed manufacturing method includes punching of an opening  44  in structural layer  38  by means of tool  46 . Those skilled in the art would appreciate in view of this disclosure that tool  46  may be any of a known variety of tools for constructing opening  44 , without departing from the scope of the present invention. As shown in  FIG. 9 , the sloped area adjacent opening  44  may then be embossed by embossing head  48 , which may be a heated tool, an ultra-sonic tool, or similar device producing heat or vibrations. As readily apparent to those skilled in the art, embossing head  48  may have the shape of an object (i.e. a defroster) being fitted within opening  44 . Embossing head  48  may also be tuned for providing a tight fit. 
   For a specific example of the first embodiment of the embossed manufacturing method, embossing head  48  may include the operational properties described below. 
   Specifically, embossing head  48  may include a head engagement force sufficient enough to crush the foam layer (i.e. 1 Kg per cm of embossed perimeter, however more force would also be acceptable as needed). For the head heat cycling, the embossing head may be preferably heated to 315-335° F. (for material such as T.P.O.) at the initial moment of contact with the top layer of structural layer  38 . Once head  48  contacts the top layer, head  48  may be held in contact with the material for a dwell time of 12 seconds and then cooled to approximately 190° F. (or less) prior to retracting. 
   In order to heat and cool embossing head  48  to the aforementioned temperature parameters, hot and cold oil (and other means know in the art) may be utilized. Specifically, a hot temperature controlled oil circuit (not shown) may be connected to each head by shifting a dedicated control valve for each particular head. Once a thermocouple (not shown) confirms the target temperature has been reached, head  48  may be advanced to contact the top layer of structural layer  38 . After the required dwell time, each oil control valve may be shifted, thereby connecting the heads to a cool oil temperature controlled oil circuit. Further, after the thermocouple for head  48  indicates the required maximum retraction temperature has been reached, head  48  may be retracted from structural layer  38 . 
   Generally, head  48  may be machined out of metal (i.e. Aluminum), with an exemplary thickness of approximately 12 mm so that sufficient volume would be provided for the drilling of an oil heating/cooling loop, which may be in the form of short flexible braided oil lines connecting each head to its oil control valve, thus minimizing the volume of oil to be flushed upon switching from heat to cooling for instance. The oil control valves may be piped to engage either oil from a hot temperature controlled circuit, or oil from a cool temperature controlled circuit. Head  48  may further be treated with TEFLON for a non-stick release. 
   The completed embossed and punched construction is shown in  FIG. 10 , and includes a sharp edge feature  50 . Referring next to  FIGS. 11 and 12 , an object  52  may be fitted within opening  44  and may include a small radius (i.e. 0.5 mm) at bezel  54 , and further include sloped edge  56 , the slope angle of which corresponds to the slope of surface  58  of structural layer  38 . Object  52  may further include standard hooks  60  for retention thereof with structural layer  38 . 
   Thus referring to  FIGS. 1 ,  2 ,  11  and  12 , the embossed and punched construction according to the present invention thus allows installation of objects (i.e. side window defrosters) as shown to provide a high quality fit (very tight edge radii, small gaps and surface flushness), as compared to objects installed per existing mold behind or vacuum wrapped technology illustrated in  FIGS. 3A-3C  (see also object  52  in  FIG. 1 ). Thus, referring to  FIGS. 13-16 , as discussed above with reference to  FIGS. 11 and 12 , the embossed and punched construction according to the present invention allows installation of objects  52 , such as defrosters, speaker grills, arm rest attachments, handle modules, bins, buttons, lock bezels and control panels, to provide a high quality fit (very tight edge radii, gaps and flushness), as compared to objects installed per existing mold behind or vacuum wrapped technology illustrated in  FIGS. 3A-3C . 
   Specifically, compared to objects installed per existing mold behind or vacuum wrapped technology for which interfaces include excessively rounded joints having radii &gt;2.5 mm and mating components, such as components  62 ,  64  are either raised above the interface (i.e.  FIG. 3A , component  62 ) or well below the main panel surface (i.e.  FIG. 3B  or  3 C, component  64 ), the embossed manufacturing method according to the present invention provides an interface with a much tighter fit appearance. For example, referring to  FIGS. 13-16 , for the embossed manufacturing method according to the present invention, panel interfaces include well formed rounded joints having radii &lt;0.5 mm, and gaps between various components are extremely tight. As shown in  FIGS. 14 and 15 , the bezel edge radius is &lt;1.75 mm. As shown in  FIGS. 16A-16C , the manufacturing method according to the present invention thus delivers a panel edge interface radius  68  of &lt;0.5 mm and a gap  66  of &lt;0.125 mm. 
   Thus, the embossed manufacturing method according to the present invention delivers extremely tight radii at the edge areas for allowing the surface of an installed object to made flush with the panel structure in a cost-effective and efficient manufacturing procedure outlined above. 
   The second embodiment of the embossed manufacturing method according to the present invention will now be described in detail with reference to  FIGS. 17-21 . 
   Specifically, as shown in  FIGS. 17 and 18 , the first step in the second embodiment of the embossed manufacturing method may include the use of injection molded foundation  70 , which may then be vacuum wrapped (as opposed to the injection molded construction of the first embodiment) with two or three layers of grained decorative laminates  72 ,  74 . At least one of the layers  72 ,  74  may be a soft (foamed) product for providing an adequate resilience and softness to the instrument panel or other component being manufactured. Further, laminates  72 ,  74  may be of similar construction as layers  24 ,  28  discussed above for the first embodiment. 
   As with the first embodiment, the vacuum wrapped structure of  FIG. 18  may then be punched by means of tool  76  (or otherwise cut) to produce an opening  79  as shown in  FIG. 19 , and thereafter embossed by means of tool  78  as shown in  FIG. 20 . The resulting embossed and punched construction is shown in  FIG. 21 . Embossing tool  78  of  FIG. 20  may be tuned for providing a tight fit. 
   For a specific example of the second embodiment of the embossed manufacturing method, embossing tool  78  may include the operational properties described below. 
   Specifically, embossing tool  78  may include a head engagement force sufficient enough to crush the foam layer (i.e. 1 Kg per cm of embossed perimeter, however more force would also be acceptable as needed). For the head heat cycling, the embossing head may be preferably heated to 315-335° F. (for material such as T.P.O.) at the initial moment of contact with the top layer of the structural layer. Once tool  78  contacts the top layer, tool  78  may be held in contact with the material for a dwell time of 12 seconds and then cooled to approximately 190° F. (or less) prior to retracting. 
   In order to heat and cool embossing tool  78  to the aforementioned temperature parameters, hot and cold oil (and other means know in the art) may be utilized. Specifically, a hot temperature controlled oil circuit (not shown) may be connected to each head by shifting a dedicated control valve for each particular head. Once a thermocouple (not shown) confirms the target temperature has been reached, tool  78  may be advanced to contact the top layer of the structural layer. After the required dwell time, each oil control valve may be shifted, thereby connecting the heads to a cool oil temperature controlled oil circuit. Further, after the thermocouple for tool  78  indicates the required maximum retraction temperature has been reached, tool  78  may be retracted from the structural layer. 
   Generally, tool  78  may be machined out of metal (i.e. Aluminum), with an exemplary thickness of approximately 12 mm so that sufficient volume would be provided for the drilling of an oil heating/cooling loop, which may be in the form of short flexible braided oil lines connecting each head to its oil control valve, thus minimizing the volume of oil to be flushed upon switching from heat to cooling for instance. The oil control valves may be piped to engage either oil from a hot temperature controlled circuit, or oil from a cool temperature controlled circuit. Tool  78  may further be treated with TEFLON for a non-stick release. 
   As discussed above for the first embodiment and illustrated in  FIGS. 11 and 12 , an object  52  fitted within opening  79  may include a small radius (i.e. &lt;0.5 mm) at the bezel thereof. Thus referring to  FIGS. 2 ,  3 A- 3 C,  11  and  12 , the embossed and punched construction according to the second embodiment of the embossed manufacturing method thus allows installation of objects as shown to provide a high quality fit (very tight edge radii, small gaps and surface flushness), as compared to objects installed per existing mold behind or vacuum wrapped technology illustrated in  FIGS. 3A-3C  (see also object  52  in  FIG. 1 ). Thus, referring to  FIGS. 13-16 , as discussed above with reference to  FIGS. 11 and 12 , the embossed and punched construction according to the present invention allows installation of objects, such as defrosters, speaker grills, arm rest attachments, handle modules, bins, buttons, lock bezels and control panels, to provide a high quality fit (very tight edge radii, gaps and flushness), as compared to objects installed per existing mold behind or vacuum wrapped technology illustrated in  FIGS. 3A-3C . 
   Specifically, compared to objects installed per existing mold behind or vacuum wrapped technology for which interfaces include excessively rounded joints having radii &gt;2.5 mm and mating components, such as components  62 ,  64  are either raised above the interface (i.e.  FIG. 3A , component  62 ) or well below the main panel surface (i.e.  FIG. 3B  or  3 C, component  64 ), the embossed manufacturing method according to the present invention provides an interface with a much tighter fit appearance. For example, referring to  FIGS. 13-16 , for the embossed manufacturing method according to the present invention, panel interfaces include well formed rounded joints having radii &lt;0.5 mm, and gaps between various components are extremely tight. As shown in  FIGS. 14 and 15 , the bezel/adjoining panel radius is &lt;1.75 mm. As shown in  FIGS. 16A-16C , the manufacturing method according to the present invention thus delivers a panel interface radius  68  of &lt;0.5 mm and a gap  66  of &lt;0.125 mm. 
   In summary, the first and second embodiments of the embossed manufacturing method according to the present invention delivers extremely tight radii at the edge areas for allowing the surface of an installed object to be made flush with the panel structure in a cost-effective and efficient manufacturing procedure as outlined above, regardless of whether, for example, the instrument panel structure is formed in by means of injection molding or vacuum wrapping. 
   While the first and second embodiments of the embossed manufacturing sequences described above have been used to discuss the manufacture of an instrument panel, it should be understood that the embossed manufacturing sequence may also be used for door liner openings (for speaker grills, arm rest attachments, handle modules, bins, buttons, lock bezels and control panels), and door liner edge details in exactly the same manner, and for a variety of other components for automobiles and other transportation means such as boats, aircraft and the like. 
   Although particular embodiments of the invention have been described in detail herein with reference to the accompanying drawings, it is to be understood that the invention is not limited to those particular embodiments, and that various changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims.