Patent Publication Number: US-2021162918-A1

Title: Mold assembly for an overhead console button carrier having a unitary body

Description:
RELATED APPLICATION 
     This application is a division of U.S. patent application Ser. No. 15/977,416 filed on 11 May 2018, the full disclosure of which is incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     This document relates generally to the motor vehicle equipment field and, more particularly, to a new and improved overhead console button carrier that has a unitary body as well as to a method of making that overhead console button carrier and to a mold assembly for that purpose. 
     BACKGROUND 
     An overhead console button carrier is a relatively complex component that functions to retain push buttons and other components such as right hand and left hand collimators and various intrusion sensors. In the past it has been necessary to assemble the overhead console button carrier from multiple parts. Such a manufacturing approach has required multiple mold tools, associated fasteners, and assembly labor all adding to the cost of producing an overhead console button carrier. 
     This document relates to a new and improved overhead console button carrier having a unitary body that includes one or more light collimators, one or more intrusion sensor brackets as well as one or more zero draft button guides. For purposes of this document, the terminology “unitary body” refers to a body originally manufactured in one piece and not requiring assembly from multiple component parts. Advantageously, an overhead console button carrier incorporating a unitary body substantially reduces the complexity and costs of production and, therefore, represents a significant advance in the art. 
     SUMMARY 
     In accordance with the purposes and benefits as described herein, a new and improved overhead console button carrier is provided. That overhead console button carrier comprises a unitary body including a first light collimator, a first intrusion sensor bracket and a first button guide. 
     The overhead console button carrier may also include a second light collimator. The overhead console button carrier may also include a second intrusion sensor bracket. The overhead console button carrier may also include a third intrusion sensor bracket. The overhead console button carrier may also include a plurality of button guides. 
     The first button guide may have a first centerline axis oriented along a first direction vector. The first light collimator may have a second centerline axis oriented along a second direction vector different from the first direction vector. The second light collimator may have a third centerline axis oriented along a third direction vector different from the first and second direction vectors. 
     The first intrusion sensor bracket may have a fourth centerline axis oriented along a fourth direction vector different from the first, second and third direction vectors. The second intrusion sensor bracket may have a fifth centerline axis oriented along a fifth direction vector different from the first, second, third and fourth direction vectors. The third intrusion sensor bracket may have a sixth centerline axis oriented along a sixth direction vector different from the first, second, third, fourth and fifth direction vectors. 
     In accordance with an additional aspect, a method is provided for making an overhead console button carrier having a unitary body. That method includes the steps of closing a mold assembly, injecting plastic into the mold assembly, forming the overhead console button carrier as a unitary body including a first light collimator, a first intrusion sensor bracket and a first button guide, opening the mold assembly and removing the overhead console button carrier from the mold assembly. 
     The method may further include the step of forming the unitary body with a second light collimator, a second intrusion sensor bracket and a third intrusion sensor bracket before opening the mold assembly. Further, the method may include the step of using a zero draft core insert to form the first button guide. Additional zero draft core inserts may be utilized to form additional button guides if desired or needed for any particular application. 
     Still further, the method may include the step of using a first core side buried retractor mechanism to form the first light collimator. Further, the method may include the step of using a second core side buried retractor mechanism to form the second light collimator. 
     In addition, the method may include the step of using a first slide mechanism, carried on a core side of the mold assembly, to form the first intrusion sensor bracket. The method may include the step of using a second slide mechanism, carried on the core side of the mold assembly, to form the second intrusion sensor bracket. The method may include the step of using a third slide mechanism, carried on the core side of the mold assembly, to form the third intrusion sensor bracket. 
     In accordance with still another aspect, a new and improved mold assembly is provided. That mold assembly may be adapted for producing an overhead console button carrier having a unitary body. The mold assembly comprises a cavity side and a core side. The core side includes at least one zero draft core insert, a first buried retractor mechanism and a first slide mechanism. 
     Further, the core side of the mold assembly may further include a second buried retractor mechanism. The core side of the mold assembly may further include a second slide mechanism. The core side of the mold assembly may include a third slide mechanism. 
     In the following description, there are shown and described several preferred embodiments of the overhead console button carrier, the method of making an overhead console button carrier and a mold assembly that may be utilized to make the overhead console button carrier. As it should be realized, the overhead console button carrier, the method and the mold assembly are capable of other, different embodiments and their several details are capable of modification in various, obvious aspects all without departing from the overhead console button carrier, the method and the mold as set forth and described in the following claims. Accordingly, the drawings and descriptions should be regarded as illustrative in nature and not as restrictive. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING FIGURES 
       The accompanying drawing figures incorporated herein and forming a part of the specification, illustrate several aspects of the overhead console button carrier, the related method and the mold assembly and together with the description serve to explain certain principles thereof. 
         FIG. 1  is a perspective view of the overhead console button carrier having a unitary body. 
         FIG. 2  is a top plan view of the overhead console button carrier illustrated in 
         FIG. 1 . 
         FIG. 3  is a bottom plan view of the overhead console button carrier illustrated in  FIGS. 1 and 2 . 
         FIG. 4 a    is a top plan view of the core side of the mold assembly that is utilized to mold the overhead console button carrier illustrated in  FIGS. 1-3 . 
         FIG. 4 b    is a top plan view of the finished overhead console button carrier resting in the core side of the mold assembly illustrated in  FIG. 4 a    following molding. 
         FIG. 5  is a top plan view of the cavity side of the mold assembly utilized to make the overhead console button carrier illustrated in  FIGS. 1-3 . 
     
    
    
     Reference will now be made in detail to the present preferred embodiments of the overhead console button carrier, the method of making that overhead console button carrier and the mold assembly for making that overhead console button carrier, examples of which are illustrated in the accompanying drawing figures. 
     DETAILED DESCRIPTION 
     Reference is now made to  FIGS. 1-3  illustrating the new and improved overhead console button carrier  10 . That overhead console button carrier  10  includes a unitary body  12 . That unitary body  12  is directly molded in one piece rather than being assembled from a plurality of component parts. As a result, the overhead console button carrier  10  may be produced in a simple and inexpensive manner (not previously thought possible) while still allowing for complex functionality. 
     In the illustrated embodiment, the unitary body  12  includes a first light collimator  14 , a second light collimator  16 , a first intrusion sensor bracket  18 , a second intrusion sensor  20 , a third intrusion sensor bracket  22  and a first button guide  24 . Still further, the unitary body  12  further includes a second button guide  26 , a third button guide  28 , a fourth button guide  30 , a fifth button guide  32  and a sixth button guide  34 . Each of the button guides  24 ,  26 ,  28 ,  30 ,  32 ,  34  includes zero draft to insure the proper operation of any push buttons subsequently incorporated therein that are adapted for operation of various electrical systems of a motor vehicle into which the overhead console button carrier  10  is incorporated. 
     As illustrated in  FIGS. 1-3 , the first button guide  24  has a first centerline axis C 1  that is oriented along a first direction vector. The second, third, fourth, fifth and sixth button guides  26 ,  28 ,  30 ,  32 ,  34  also have their own unique centerline axes oriented parallel to the first centerline axis C 1 . The first light collimator  14  has a second centerline axis C 2  oriented along a second direction vector different from the first direction vector. The second light collimator  16  has a third centerline axis C 3  oriented along a third direction vector different from the first and second direction vectors. 
     The first intrusion sensor bracket  18  has a fourth centerline axis C 4  oriented along a fourth direction vector different from the first, second and third direction vectors. The second intrusion sensor bracket  20  has a fifth centerline axis C 5  oriented along a fifth direction vector different from the first, second, third and fourth direction vectors. Finally, the third intrusion sensor bracket  22  has a sixth centerline axis C 6  oriented along a sixth direction vector different from the first, second, third, fourth and fifth direction vectors. 
     Reference is now made to  FIGS. 4 a , 4 b    and  5  which illustrate the mold assembly  50  utilized to make the overhead console button carrier  10 . That mold assembly  50  includes a cavity side  52  and a core side  54 . The core side  54  includes at least one zero draft core insert  56 . More particularly, in the illustrated embodiment, the core side  54  includes the first zero draft insert  56 , a second zero draft core insert  58 , a third zero draft core insert  60 , a fourth zero draft core insert  62 , a fifth zero draft core insert  64  and a sixth zero draft core insert  66 . 
     The first zero draft core insert  56  forms the first button guide  24 . The second zero draft core insert  58  forms the second button guide  26 . The third zero draft core insert  60  forms the third button guide  28 . The fourth zero draft core insert  62  forms the fourth button guide  30 . The fifth zero draft core insert  64  forms the fifth button guide  32 . Finally, the sixth zero draft core insert  66  forms the sixth button guide  34 . All of the button guides  24 ,  26 ,  28 ,  30 ,  32 ,  34  have their own centerline axis offset from and parallel to each of the others. 
     The core side  54  also includes a first buried retractor mechanism  68  and a second buried retractor mechanism  70 . Further, the core side  54  includes a first slide mechanism  72 , a second slide mechanism  74  and a third slide mechanism  76 . The first buried retractor mechanism  68  forms the first light collimator  14 . The second buried retractor mechanism  70  forms the second light collimator  16 . The first slide mechanism  72  forms the first intrusion sensor bracket  18 . The second slide mechanism  74  forms the second intrusion sensor bracket  20 . The third slide mechanism  76  forms the third intrusion sensor bracket  22 . 
     Retractor mechanisms,  68 ,  70  and slide mechanisms  72 ,  74 ,  76  of the type utilized in the mold assembly  50  described herein are available from various manufacturers/suppliers of mold assemblies. While such retractor mechanisms  68 ,  70  and slide mechanisms  72 ,  74 ,  76  are known to those skilled in the art of mold design, it is believed that the present mold assembly  50  is the first to incorporate retractor mechanisms and slide mechanism with one or more zero draft core inserts  56 ,  58 ,  60 ,  62 ,  64 ,  66 . It is the unique and novel combination of the actions provided by the retractor mechanisms  68 ,  70  and the slide mechanisms  72 ,  74 ,  76  with the zero draft core inserts  56 ,  58 ,  60 ,  62 ,  64 ,  66  that allows the consolidation of the overhead console button carrier  10  into a unitary body  12 . 
     It is the synergistic combination of actions provided by the first and second buried retractor mechanisms  68 ,  70 , and the first, second and third slide mechanisms  72 ,  74 ,  76  in combination with the zero draft inserts  56 ,  58 ,  60 ,  62 ,  64 ,  66  that allows for the complex structure of the overhead console button carrier  10  to be manufactured with a unitary body  12  that fully functions to orient the button guides  24 ,  26 ,  28 ,  30 ,  32 ,  34  to receive and allow for proper operation of push buttons, the first and second light collimators  14 ,  16  to receive and allow for proper operation and function of map lights and the first, second and third intrusion sensor brackets  18 ,  20 ,  22  to receive and allow for proper operation and function of intrusion sensors oriented along specific direction vectors as required for proper and effective operation. 
     The method of making the overhead console button carrier  10  comprises the steps of: (a) closing the mold assembly  50 , (b) injecting plastic into the mold assembly, (c) forming the overhead console button carrier  10  as a unitary body  12  including a first light collimator  14 , a first intrusion sensor bracket  18  and a first button guide  24 , (d) opening the mold assembly and (e) removing the overhead console button carrier  10  from the mold assembly. 
     The method may further include the step of forming the unitary body  12  with a second light collimator  16 , a second intrusion sensor bracket  20  and a third intrusion sensor bracket  22  before opening the mold assembly. In addition the method may include using a zero draft core insert  56  to form the first button guide  24 . 
     A second zero draft core insert  58  may be utilized to form the second button guide  26 . A third zero draft core insert  60  may be utilized to form the third button guide  28 . A fourth zero draft core insert  62  may be utilized to form the fourth button guide  30 . A fifth zero core draft insert  64  may be utilized to form the fifth button guide  32 . A sixth zero draft core insert  66  may be utilized to form the sixth button guide  34 . All zero draft core inserts  56 ,  58 ,  60 ,  62 ,  64 ,  66  are offset from and parallel to one another, perpendicular to the mold assembly part line. 
     The method may include utilizing the first core side buried retractor mechanism  68  to form the first light collimator  14 . The method may include utilizing the second core side buried retractor mechanism  70  to form the second light collimator. 
     The method may include using the first slide mechanism  72 , carried on the core side  54  of the mold assembly  50 , to form the first intrusion sensor bracket  18 . The method may include using the second slide mechanism  74 , carried on the core side  54  of the mold assembly  50 , to form the second intrusion sensor bracket  20 . Further the method may include using the third slide mechanism  76 , carried on the core side  54  of the mold assembly  50 , to form the third intrusion sensor bracket  22 . 
     The foregoing has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the embodiments to the precise form disclosed. Obvious modifications and variations are possible in light of the above teachings. All such modifications and variations are within the scope of the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled.