Patent Publication Number: US-2007119037-A1

Title: Process for manufacturing armrests

Description:
FIELD OF THE INVENTION  
      The present invention relates to the field of manufacturing components for automobiles. In particular, it relates to an improved process for manufacturing partially deformable or soft-topped armrests.  
     BACKGROUND OF THE INVENTION  
      Soft-topped console armrests for automobiles can be manufactured and assembled in several different ways. In one method, the final assembly takes place by taking a manufactured armrest “skin” or soft cover (e.g. injection moulded PVC) and then stretching or otherwise engaging it over the solid substrate (typically plastic) of the armrest and adding a secondary cover or closeout. The armrest is then secured to the console, possibly with additional elements such as a hinge and latching mechanism to allow access to a storage compartment located within the console under the armrest.  
      The difficulty with the existing assembly process is that stretching the cover over the substrate requires deformation of the cover. Once stretched, the substrate may not securely engage the cover as the cover lacks full recovery from the deformation process. This can result in a loosely fitting cover that may bulge, sag or, even worse, one that comes off the substrate some time after the assembly process is complete and the automobile has reached the consumer. It is thus desirable to develop an assembly process that does not require deformation of the soft cover.  
      One method of making an armrest is disclosed in U. S. Pat. No. 5,738,810 issued to De Filippo which describes a method of manufacturing headrests and armrests by creating a pillow element covered by an upholstery sheet. The upholstery sheet extends beyond the perimeter of the pillow such that when the pillow is placed into a mould the sheet extends into the mould. The mould is then filled with foamed plastic material to form an outer body for the pillow and simultaneously secure the pillow and sheet to the body.  
      Another method is disclosed in U.S. Pat. No. 5,628,545 issued to Perthius et al. which describes a method of covering a cushion for a vehicle seat by using a non-stretch cord contained within a pleated margin of the cover. The non-stretch cord then holds the margin against the bottom of the cushion to assist in holding the cover in place.  
      Still another method is disclosed in U. S. Pat. No. 5,098,622 issued to Lilienthal et al. which describes a method of making an armrest. The armrest is formed from a two-piece structural insert which is used to first injection mould an outer vinyl skin around the first insert and then couple the second insert to the first. The whole is then placed in a foam mould and the body is created between the structure and the vinyl skin using urethane foam.  
      Based on the prior art, there is a need for a new method of assembling armrests that allows for the assembly combination of a cover and a solid structure without requiring deformation of the cover.  
     SUMMARY OF THE INVENTION  
      According to an aspect of the present invention, there is provided a process for manufacturing armrests with soft covers, comprising the steps of: a) providing a soft cover, b) providing a substrate, the substrate divided into two substrate parts, and c) attaching the cover to the substrate to form an armrest by engaging each of the two substrate parts with opposite ends of the cover and manipulating the two substrate parts such that the two substrate parts engage each other to form a unitary substrate securely covered by the cover. Ideally, the two substrate parts are identical, near identical, or mirror images of one another.  
      Preferably, the unitary substrate is then secured to a base. Additionally, a hinge and clasp can be added and opposite ends of the cover or closeout prior to attaching the cover to the substrate.  
      Preferably, the substrate parts have flanges that interlock to form the unitary substrate. These flanges may be severable after assembly of the unitary substrate.  
      According to another aspect of the invention, an armrest with a soft cover is provided as formed according to the methods described above.  
      An advantage of the present invention is that the soft cover of the armrest is not deformed during assembly, thereby allowing it to retain its shape and remain securely engage to the substrate.  
      Other and further advantages and features of the invention will be apparent to those skilled in the art from the following detailed description thereof, taken in conjunction with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      The invention will now be described in more detail, by way of example only, with reference to the accompanying drawings, in which like numbers refer to like elements, wherein:  
       FIG. 1  is a perspective view of an armrest embodying the features of the present invention along with a floor console for an automobile;  
       FIG. 2  is exploded view of the armrest of  FIG. 1 ;  
       FIG. 3  is a side view of the initial step in the process of assembling the armrest of  FIG. 1 ;  
       FIG. 4  is a side view of an intermediate step in the process of assembling the armrest of  FIG. 1 ; and  
       FIG. 5  is a side view of the final step in the process of assembling the armrest of  FIG. 1 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
      Referring now to  FIG. 1 , the soft armrest in accordance with a presently preferred embodiment of the invention is indicated generally at  10 . Soft armrest  10  is designed to be incorporated into a floor console  12  for an automobile (not shown). The soft armrest is positioned such that a driver or passenger in the automobile can rest their arm on the soft armrest  10  in comfort. Additionally, the area in the floor console  12  underneath the soft armrest  10  may be used for storage, necessitating that the soft armrest  10  have a hinge and latching mechanism to provide access to storage while ensuring that soft armrest  10  remains in position while the vehicle is in motion or in the event of an accident.  
       FIG. 2  shows an exploded view of the various components of soft armrest  10  according to the preferred embodiment for installation over a console storage space. The top consists of a soft cover  20 , which fits over a first substrate element  22  and a second substrate element  24 . The substrate elements  22  and  24  are designed to be secured to a base  26 . Additional components include a hinge  28  and a clasp  30  that allow the soft armrest  10  to be lifted to access a storage compartment inside the floor console  12  (as shown in  FIG. 1 ). The hinge  28  and clasp  30  are secured between the substrate elements  22  and  24  and the base  26 . The hinge  28  and clasp  30  can be of various types known in the art.  
      First substrate element  22  and second substrate element  24  are formed with interlocking flanges or “fingers”  32  and  34 , respectively. Fingers  32  and  34  interlock such that substrate elements  22  and  24  can be locked together into a single substrate element. For ease of manufacture, and if assembly conditions permit, it is preferable to design the substrate elements  22  and  24  with fingers  32  and  34  such that first substrate element  22  and second substrate element  24  are identical.  
       FIGS. 3, 4  and  5  illustrate the steps in attaching soft cover  20  to substrate elements  22  and  24  to form a single piece, which is then attached to base  26  to form the completer armrest  10 . As seen in  FIG. 3 , first substrate element  22  and second substrate element  24  are inserted into soft cover  20  at an angle (i.e. 45 degrees) such that the fingers  32  and  34  are protruding towards each other. The angle of the substrate elements  22  and  24  is then reduced, preferably by applying pressure in the center area between the substrate elements  22  and  24  such that the fingers  32  and  34  engage one another as shown in  FIG. 4 . The process concludes as shown in  FIG. 5 , where the angle is then reduced to zero, such that fingers  32  and  34  are fully interlocked, resulting in substrate elements  22  and  24  forming a single piece which is attached to soft cover  20 .  
      For ease of assembly, soft cover  20  may be formed with a lip or protruding edge that engages the end of the inserted substrate element to inhibit slippage or other problems during the assembly process. Likewise, substrate elements  22  and  24  may have lips or protruding edges to similarly engage the ends of soft cover  20  during the assembly process.  
      The single covered piece thus formed is then attached to base  26 , along with any intervening elements such as hinge  28  and clasp  30 , to form the desired soft armrest  10 .  
      By forming the internal substrate from two separate elements  22  and  24  and engaging them within the soft cover  20  by the process described herein, a tight fit for the soft cover  20  over the resulting substrate is assured.  
      As an alternative to the embodiment shown, particularly if the soft armrest  10  is to remain in a fixed position, the substrates  22  and  24  may be sufficient to secure the soft armrest  10  to the floor console  12  once assembled. In such a design, base  26  is not required. Hinge  28  and clasp  30  are also not required if there is no storage beneath soft armrest  10 .  
      Depending on the design of fingers  32  and  34 , they made be made severable or partially severable after locking. In this case, once the fingers are interlocked, the severable parts are removed to prevent separation of the substrates  22  and  24  after assembly.  
      This concludes the description of a presently preferred embodiment of the invention. The foregoing description has been presented for the purpose of illustration and is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching and will be apparent to those skilled in the art. It is intended the scope of the invention be limited not by this description but by the claims that follow.