Patent Publication Number: US-2006012205-A1

Title: Automotive storage compartment and method for making the same

Description:
FIELD OF THE INVENTION  
      The present invention pertains generally to automotive interiors and more particularly to storage compartments for automotive interiors.  
     BACKGROUND OF THE INVENTION  
      It is known to provide automotive interiors with various trim assemblies to improve the aesthetic appearance of the automotive interior and for the comfort and convenience of vehicle occupants. Examples of these interior trim assemblies include the instrument panels, armrests, door trim panels and consoles. In many of these trim assemblies, various storage compartments are incorporated therein that allow the vehicle occupant to conveniently store one or more items, such as tissue, coins, maps and other items typically carried in a vehicle. In many cases, such as for storage compartments in door panels, it is desirable for the compartment to include a door or cover that overlies the opening and secures the items within the compartment. The cover is typically attached to the compartment and moveable, such as by a hinge mechanism, so that the articles in the compartment may be accessed. Moreover, the cover may have additional padding coupled thereto and provide an armrest for the door panel.  
      While being desired by car owners and vehicle occupants, covered storage compartments have some drawbacks. The primary drawback is in the manufacturing and assembly of the various parts that make up the storage compartment. The current process for making a storage compartment is typically to form the compartment body in a first mold. The compartment door is then individually formed in a second and separate mold. A further separate connecting member, usually being a pair of metal or plastic cylindrical hinge pins, is then used to couple the compartment door to the compartment body. Moreover, current storage compartments typically include a pair of damping mechanisms to provide some resistance to opening and closing the door to the storage compartment. The as-formed storage compartment may then be inserted into the various trim assemblies in the automobile.  
      Thus, under current manufacturing processes, storage compartments comprise several different parts each having different part numbers that must all be appropriately supplied, tracked, shipped, inventoried and eventually assembled to make the complete product, such as a door panel or console. Multiple part assemblies in turn lead to significant administrative costs and labor costs, which increase the overall costs of production.  
      There is a need for an improved automotive storage compartment and a method for making the storage compartment that reduces the number of parts and reduces the labor required for assembly thereof, thereby reducing overall manufacturing costs.  
     SUMMARY OF INVENTION  
      The present invention provides for an improved automotive storage compartment having a reduced number of parts and that is adapted to be coupled to an interior trim assembly, such as a door panel, of a vehicle.  
      To this end, the storage compartment includes a first member, which is either a compartment body or cover, having at least one connecting member integrally formed therein and made from a first material. The storage compartment further includes a second member, which is the other of the compartment body or cover, having at least one connecting member integrally formed therein and made from a second material different from the first material. The first and second materials may include various thermoplastic materials with one of the materials having a higher melting point than the other. The at least one connecting member on the first member includes at least one projecting portion and the at least one connecting member on the second member includes at least one receiving portion that receives the at least one projecting portion. The compartment body defines a cavity having an opening adapted to store one or more items such as coins, tissue and the like. The projecting and receiving portions accordingly are pivotally coupled together so that the storage compartment cover may be opened and closed to allow access to the cavity.  
      In an exemplary embodiment, the storage compartment includes a compartment body defining a cavity having an opening and adapted to store one or more items. The compartment body further includes an integrated pair of spaced apart connecting members with each having a projecting portion extending therefrom. Each projecting portion defines a pin having an enlarged distal end configured as a circular portion. The cover similarly includes an integrated connecting member having a pair of spaced apart receiving portions with each defining a bore having an enlarged portion configured as a circular recess. Each circular recess receives one of the circular portions to couple the cover to the compartment body such that the cover is pivotally moveable between an open position, wherein the cavity is accessible through the opening, and a closed position, wherein the cover overlies the opening. The compartment body may be formed from polybutylene terephthalate or polyamide  12 . The cover may be formed from polypropylene, polyoxymethylene or polyamide  6 .  
      The automotive storage compartment may be formed by a two shot molding operation. In a first shot of the molding operation, the first material is injected into a mold to form the first member, i.e. the compartment body or cover, having the at least one integrated connecting member that includes the at least one projecting portion extending therefrom. Next, a mold chamber is formed about at least a portion of the first member, and more specifically, about a portion of the at least one projecting portion. After the first shot, the second material is injected into the mold chamber in a second shot of the molding operation to form the second member, i.e. the other of the body or cover, having the at least one integrated connecting member that includes the at least one receiving portion. The second material has a lower melting point than the first material to avoid fusion of the receiving portion to the projection portion. Accordingly, the at least one receiving portion overmolds the at least one projecting portion so that the compartment body and cover are pivotally coupled together. The storage compartment may then be incorporated into an automotive trim assembly, such as a door panel.  
      By virtue of the foregoing, there is thus provided an improved automotive storage compartment having a reduced number of parts and that is adapted to be coupled to an interior trim assembly of a vehicle.  
      The features and objectives of the present invention will become more readily apparent from the following Detailed Description taken in conjunction with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF DRAWINGS  
      The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given above, and the detailed description given below, serve to explain the invention.  
       FIG. 1  is a side perspective view of an automotive trim assembly including an embodiment of the storage compartment of the present invention in the form of a door panel;  
       FIG. 2  is a top plan view of the trim assembly of  FIG. 1  showing a cut-away portion of the storage compartment to illustrate the coupling between the cover and compartment body;  
       FIG. 2A  is an enlarged view of the incircle portion  2 A showing the coupling between the cover and compartment body of  FIG. 2 ;  
       FIG. 2B  is a figure similar to  2 A showing another embodiment of the present invention;  
       FIG. 3  is a perspective view of a mold used to form the compartment body of the storage compartment of the present invention;  
       FIG. 3A  is the first in a series of sequential cross-sectional views of the mold of  FIG. 3  taken along the lines  3 A- 3 A illustrating the first shot of the molding operation of the storage compartment;  FIG. 3B  is the second in this series of cross-sectional views;  
       FIG. 4  is a perspective view of a mold used to form the cover of the storage compartment;  
       FIG. 4A  is the first in a series of sequential cross-sectional views of the mold of  FIG. 4  taken along the lines  4 A- 4 A illustrating the second shot of the molding operation of the storage compartment;  FIG. 4B  is the second in this series of cross-sectional views; and  
       FIG. 5  is a cross-sectional view of the storage compartment of  FIG. 4B  removed from the mold and showing the cover in an open and closed position. 
    
    
     DETAILED DESCRIPTION  
      In  FIG. 1 , there is shown an interior trim assembly, in the form of a door panel  10  for an automobile (not shown), including an embodiment of the automotive storage compartment  12  of the present invention within a substrate  14  of door panel  10 . The door panel  10  covers a portion of the interior of the automobile door to provide a more aesthetically pleasing environment, as well as additional comfort to the vehicle&#39;s occupants. Other various trim assemblies in the automobile, such as instrument panels, rear passenger side panels and consoles, are generally constructed in a similar fashion and may benefit from the present invention. Thus, while the following detailed description focuses on the storage compartment  12  being included in a door panel  10 , those having ordinary skill in the art will recognize that the storage compartment  12  may equally be incorporated in other automotive trim assemblies.  
      With further reference to  FIGS. 1 and 2 , the door panel  10  includes a relatively rigid substrate  14 , which receives the storage compartment  12  and which forms at least a portion of the structural support and defines the general shape of the door panel  10 . The door panel  10  may be secured to the interior of the automobile, for example, by a bracket or mounting member (not shown) as is known in the art. The door panel  10  further includes a front surface  16  that faces the interior of the automobile and a back surface (not shown) opposite the front surface  16  that is hidden from view when the panel assembly  10  is mounted to the automobile. As shown in  FIG. 1 , storage compartment  12  may be incorporated into door panel  10  and cooperate with other features, such as armrest  18 , to hide the storage compartment  12  from view.  
      As best shown in  FIGS. 2-2A  and  4 , the storage compartment  12  includes a compartment body  20  defining a cavity  22  having an opening  24  for gaining access to the cavity  22 . The cavity  22  is adapted to store one or more items such as coins, tissue, maps and the like. The compartment body  20  further includes a pair of spaced apart connecting members  26  integrally formed therein. While two connecting members  26  are shown in  FIGS. 2 and 4 , it should be understood by those of ordinary skill in the art that one connecting member or more than two connecting members may be integrally formed with the compartment body  20 . The compartment body  20  is made of a thermoplastic material such as a thermoplastic synthetic resin. For example, the compartment body may be formed from polybutylene terephthalate or polyamide  12 .  
      As best shown in  FIGS. 2 and 5 , the storage compartment  12  also has a cover  30  including one connecting member  32  integrally formed therein. It similarly should be understood by those having ordinary skill in the art that more than one connecting member  32  may be integrally formed with the cover  30 . The cover  30  is made of a thermoplastic material such as a thermoplastic synthetic resin. For example, the cover may be formed from polypropylene, polyoxymethylene, or polyamide  6 , and further has a different melting point from the material of the body  20 . Advantageously, the cover material has a lower melting point than the compartment body material.  
      With further reference to  FIGS. 2-2A , each integral connecting member  26  of the body  20  includes a projecting portion defining a pin  34  having an enlarged distal end configured as a circular portion  36 . The integral connecting member  32  of the cover  30  includes a pair of spaced apart receiving portions defining a bore  37  having an enlarged receiving portion configured as a circular recess  38 . Accordingly, the connecting members  26  of the body  20  cooperate with the connecting member  32  of the cover  30  to couple the cover  30  to the compartment body  20 , and more specifically, each circular recess  38  receives one of the circular portions  36  to pivotally couple the cover  30  to the compartment body  20  such that the cover  30  is moveable, as shown in  FIG. 5 , between an open position, wherein the cavity  22  is accessible through the opening  24 , and a closed position, wherein the cover  30  overlies the opening  24 .  
      It should be understood that the projecting portions  34  and receiving portions  37  can comprise any multitude of desired shapes and sizes for pivotally coupling together the body  20  and cover  30 . By way of example,  FIG. 2B  shows another embodiment of the storage compartment  12  wherein the pin  34  is devoid of the circular portion  36  while the corresponding bore  37  similarly is devoid of the circular recess  38 . Accordingly, the bore  37  receives the pin  34  to pivotally couple the cover  30  to the compartment body  20 . It also should be understood that the body connecting members  26  may include more than one projecting portion  34  and the cover connecting member  32  may include any number of corresponding receiving portions  37 . It is further understood that the cover  30 , alternatively, could be provided with one or more projecting portions  34  while the compartment body  20 , alternatively, could be provided with one or more integrated receiving portions  37 .  
      The storage compartment  12  may further include one or more hinge springs (not shown) cooperating with the body  20  and the cover  30  to assist with movement of the cover  30  from the open position to the closed position.  
      With reference to  FIGS. 3-5 , a method of making the storage compartment  12  of the present invention will now be described. More specifically, the storage compartment  12  is formed by a two-shot molding operation wherein a first shot molds one of either the compartment body  20  or the cover  30 , and wherein a second shot molds the other of the body  20  or cover  30  to couple the parts together. To this end, and as shown in  FIG. 3 , a first mold  50  is shown including a top portion  52  and a bottom portion  54  defining a first cavity  56  adapted to mold a first member, i.e. the compartment body  20 , in a first shot. In  FIG. 4 , a second mold  60  is shown including a top portion  62  and bottom portion  64  defining a cavity  66  adapted to mold a second member, i.e. the cover  30 , in a second shot. While the first and second molds  50 ,  60  are illustrated separately, it should be understood that the first and second molds  50 ,  60  may be provided together in a single mold assembly as is well known in the art.  
      As best shown in  FIGS. 3A and 3B , to mold the compartment body  20 , the first mold  50  is closed and a first curable material  70  is injected through a channel  72 , in a first shot, into the space formed between the top and bottom portions  52 ,  54 . The first curable material  70  advantageously is a thermoplastic material such as polybutylene terephthalate and polyamide  12 . The injected material  70  is allowed sufficient time to at least partially cure to form the compartment body  20 .  
      As best shown in  FIGS. 3B and 4 , the molded body  20  defines the cavity  22  having the opening  24  for gaining access thereto. This cavity  22  is adapted to store one or more items such as coins, tissue, maps and the like. The compartment body  20  further includes the pair of integrally formed, spaced apart connecting members  26  with each having the projecting portion extending therefrom defining the pin  34  having the enlarged distal end configured as the circular portion  36 .  
      With further reference to  FIG. 4 , after the body  20  is molded in  FIG. 3B , the body  20  is moved to the second mold  60 . Movement of the body  20  to the second mold  60  can occur by methods commonly known in the art such as by hand, i.e. manually, by robotic means, or by utilizing a rotating mold assembly. With respect to the rotating mold assembly (not shown), the first member, e.g. the body, may be formed in a first mold as stated above. The mold is then opened and the first member, rather than being manually or robotically moved, is rotated, e.g. 180 degrees, on a rotating platen to coordinate with a second mold to form the second member, e.g. the cover. The rotating mold assembly advantageously allows for simultaneous molding of first and second members.  
      As best shown in  FIGS. 4A and 4B , after the body  20  has been moved to the second mold  60 , a portion of the connecting members  26 , and more specifically, a portion of the projecting portions  34  are received within the cavity  66  of the second mold  60  that is adapted to mold the cover  30 . Notably, the second mold  60  is closed to form a mold chamber  82  about a portion of the projecting portions  34 . A second curable material  84  is then injected through a channel  86 , in a second shot, into the space, i.e. the mold chamber  82 , formed between the top and bottom portions  62 ,  64 . This second curable material  84  has a lower melting point than the first curable material  70 . Accordingly, the second material  84  is provided at a lower temperature than the melting point of the first material  70  so as to avoid fusion of the circular recess  38  to the circular portion  36 . The second material  84  advantageously is a thermoplastic material such as polypropylene, polyoxymethylene, polyamide  6  or other suitable materials.  
      As further shown in  FIGS. 4B and 5 , the injected material  84  is allowed sufficient time to cure to form the cover  30  at a position  180  degrees relative to the body  20 . After the storage compartment  12  is formed, the mold  60  may be opened and the storage compartment  12  ejected therefrom. Accordingly, the cover  30  includes the integrally formed connecting member  32  including the pair of spaced apart receiving portions defining the bore  37 . Each bore  37  has the enlarged receiving end defining the circular recess  38  overmolding the circular portions  36  so that the compartment body  20  and cover  30  are pivotally coupled together. As best shown in  FIG. 5 , the cover  30  of the formed storage compartment  12  is moveable between the open position, wherein the cavity  22  is accessible through the opening  24 , and the closed position, wherein the cover  30  overlies the opening  24 . Notably, the first and/or second curable materials  70 ,  84  further may be selected based upon a desired shrinkage property to provide for varying degrees of friction between the projecting portions  34  and receiving portions  37  to alter the ease with which the cover  30  may be opened and closed.  
      One or more hinge springs (not shown) further may be provided to cooperate with the body  20  and the cover  30  to assist with movement of the cover  30  from the open position to the closed position.  
      Advantageously, the molding operation of the present invention may be continuously performed utilizing a single mold assembly to provide an improved automotive storage compartment. The molded storage compartment  12 , as shown in  FIG. 1 , may now be received within substrate  14  of the door panel  10 . It should be recognized that additional manufacturing operations may be performed on storage compartment  12 . For example a foam pad may be coupled to the top surface of cover  30  so that cover  30  further performs as an armrest  18  for door panel  10 . Those having ordinary skill in the art will recognize that the storage compartment  12  may equally be included in the substrates of other automotive trim assemblies, e.g. instrument trim panels, rear passenger side panels, center consoles and others.  
      Although the above method has described molding the first member as the body  20  and molding the second member as the cover  30 , it should be understood that the cover  30 , alternatively, could be molded as the first member while the compartment body  20 , alternatively, could be molded as the second member. It is further understood that the receiving portions  37 , alternatively, may be formed with the first member while the projecting portions  34  alternatively may be formed with the second member.  
      While the present invention has been illustrated by the description of the various embodiments thereof, and while the embodiments have been described in considerable detail, it is not intended to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and methods and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the scope or spirit of Applicants&#39; general inventive concept.