Patent Description:
One type of closure used in vehicle interiors is a tambour door. Tambour doors may be used to selectively cover and uncover some other part of the vehicle interior where there is limited space in which other types of closures such as hinged doors cannot function. Tambour doors have an articulated construction that permit the door to bend as it moves along a curved path. One example of a tambour door is disclosed in <CIT> to Laskey. Laskey discloses a tambour door made in a multi-shot injection molding process. A relatively rigid substrate is molded in a first mold cavity, and that molding is placed in a second mold cavity for overmolding a softer skin layer over the top of the substrate. The Laskey process thus requires two injection molding steps. In addition, both of the substrate and the skin layer of Laskey have a segmented configuration-that is, the thickness of both of the molded layers is non-uniform in the direction of door movement, making it visibly apparent from its exterior that the door is a tambour door. <CIT> discloses trim element that comprises a movable curtain extending between a first end and a second end, a light guide element extending in the curtain comprising an inlet end piece, a light source arranged to inject light into the guiding element via the inlet end piece. At least a portion of the inlet end piece is movable in a light guide when the curtain moves between the open position and the closed position of the curtain.

In accordance with various embodiments, a vehicle interior assembly includes a tambour door that is moveable along end guides of the assembly between an open position and a closed position. The tambour door includes a plurality of slats interconnected by a unidirectional cord embedded in a plastic material of each one of the slats, wherein the cord is molded-in to each one of the slats.

In various embodiments, the cord includes a yarn including bundled strands.

In various embodiments, the cord includes synthetic fibers.

In various embodiments, the cord includes synthetic fibers that have a glass transition temperature higher than the plastic material.

In various embodiments, the cord includes synthetic fibers including aramid fibers.

In various embodiments, the plastic material completely surrounds the cord.

In various embodiments, each slat includes opposite ends and a central portion extending between the opposite ends. The central portion is made from the same plastic material in which the cord is embedded.

In various embodiments, the slats are spaced apart such that one slat is not connected to an adjacent slat by the plastic material.

In various embodiments, the slats are spaced apart such that one slat is not connected to an adjacent slat by any molded material.

In various embodiments, the tambour door includes a decorative layer coupled with one side of the slats to move together with the slats during movement of the door between the open and closed positions.

In various embodiments, the tambour door includes a decorative layer that is a non-segmented layer.

In various embodiments, the tambour door includes a decorative layer including a natural wood layer.

In various embodiments, a method of making the vehicle interior assembly includes the steps of supporting the unidirectional cord in a cavity of a closed slat molding tool, and filling the cavity with the plastic material to embed the cord in the plastic material to make a substrate of the tambour door. The substrate is subsequently assembled to the end guides to form the vehicle interior assembly.

In various embodiments, at least a portion of a clamp load between first and second portions of the closed molding tool is not applied to the cord during making the vehicle interior assembly.

It is contemplated that any number of the individual features of the above-described embodiments and of any other embodiments depicted in the drawings or description below can be combined in any combination to define an invention, except where features are incompatible.

Illustrative embodiments will hereinafter be described in conjunction with the following figures, wherein like numerals denote like elements, and wherein:.

Described below is a vehicle interior assembly including a tambour door made in an elegantly simple manner with fewer parts and fewer assembly steps than in the prior art. With reference to <FIG>, a portion of a vehicle interior assembly <NUM> is illustrated, including a support assembly <NUM> and a tambour door <NUM> supported by the support assembly. As illustrated in the exploded view of <FIG>, the support assembly <NUM> may include opposite first and second portions <NUM>, <NUM> that are assembled together with the tambour door <NUM> therebetween. Each of these portions <NUM>, <NUM> includes a respective end guide <NUM>, <NUM> configured to act as guides for tambour door <NUM> movement between the illustrated closed position and an open position, in which the tambour door is moved in direction A to provided access to an area which is concealed when the door <NUM> is in the closed position.

The illustrated support assembly <NUM> and tambour door <NUM> are part of a vehicle center console as the vehicle interior assembly <NUM>. The end guides <NUM>, <NUM> of the support assembly <NUM> in this case include grooves or slots in which respective transverse ends <NUM>, <NUM> of the tambour door <NUM> are constrained such that the guides define the instant location and allowable movement of the door. Door movement along the top side of the assembly is in the longitudinal direction (y) of the vehicle. Door movement along a rear side of the assembly is in the longitudinal (y) and vertical (z) directions. The direction A of door movement is a curvilinear direction. As discussed further below, the tambour door <NUM> has an articulated construction such that it changes between a generally flat or planar configuration when in the closed position and a curved or bent configuration when in the open position. In this example, the opposite ends <NUM>, <NUM> of the door <NUM> are essentially posts or protrusions slidingly engaged with the groove-like end guides <NUM>, <NUM>. In other examples, the arrangement is reversed, with the ends <NUM>, <NUM> of the door <NUM> including grooves or slots that are guided by a rails or other protrusions as the guides <NUM>, <NUM>. The guides <NUM>, <NUM> and/or the ends <NUM>, <NUM> may include low-friction surfaces, inserts, or coverings or may include rotational members such as wheels to make movement of the door <NUM> along the support assembly <NUM> relatively frictionless.

The support assembly <NUM> may be mounted along opposing left and right interior walls of a console storage area. In other examples, interior walls of the console may include the end guides <NUM>, <NUM> as integral features. The vehicles interior assembly <NUM> may also be something other than a vehicle console. The tambour door <NUM> may for example conceal a touch screen of an instrument panel in the closed position, for example, and reveal the touch screen when moved to the open position. In this manner, the tambour door <NUM> essentially acts as a closure or concealing element that hides things from view when those things are not needed, including functional vehicle elements or access to a storage area. The tambour door <NUM> could also be used to selectively open or close HVAC intake or discharge ports, or to selectively block sunlight or visibility into or out of the vehicle interior. In any case, the articulated nature of the tambour door <NUM> facilitates its use in applications where the available space is too limited for a hinged-type closure and permits the door to be completely hidden when in the open position if so desired by vehicle interior designers.

The tambour door <NUM> includes a substrate <NUM> and a decorative layer <NUM> disposed over and coupled with the substrate. In this example, the decorative layer <NUM> is coupled with the underlying substrate <NUM> via a bonding layer <NUM>, such as an adhesive layer or a cushioning layer having its opposite sides bonded with the back side of the decorative layer <NUM> and the outer side of the substrate <NUM>. The substrate <NUM> has an articulated construction while, in this example, the decorative layer <NUM> is non-articulated. That is to say that the decorative layer <NUM> is a solid layer with a uniform thickness relying on its own flexibility for movement with the underlying articulated substrate <NUM>. The decorative layer <NUM> presents a decorative surface to the vehicle interior and may be made from or include any number of materials, such as leather, a polymeric simulated leather, a simulated wood or metal material, or a natural material.

In one embodiment, the decorative layer <NUM> includes or is a natural wood layer, such as a wood veneer, made sufficiently thin to be able to flex to follow the profile of the end guides <NUM>, <NUM> as the door <NUM> moves between the open and closed positions. The decorative layer <NUM> may be non-segmented or non-articulated, with a uniform thickness along its entire length and width. In this manner, the tambour door <NUM> has a non-tambour appearance to an observer and may thus blend in with other adjacent or surrounding decorative materials of the vehicle interior when the door <NUM> is in the closed position. The illustrated door <NUM> also includes a handle <NUM> attached to the substrate <NUM> and extending through the decorative layer <NUM> to facilitate manual door movement. Door movement may also be automated via a motor or other actuator.

With reference to the plan view of <FIG>, the substrate <NUM> of the tambour door <NUM> is of relatively simple construction, including a plurality of slats <NUM> and one or more unidirectional cords <NUM> embedded in a plastic material of each one of the slats. The opposite ends <NUM>, <NUM> of the door <NUM> are provided by the substrate <NUM> and are opposite transverse ends in this example. The door also has opposite longitudinal ends <NUM>, <NUM> spaced apart along the curvilinear direction of movement (A). In one embodiment, all of the plurality of slats <NUM> are molded slats (e.g., injection molded) made from a single plastic material in a single molding cycle. A handle portion <NUM> of the substrate <NUM> may also be fabricated in the same molding cycle as the slats <NUM>. The unidirectional cords <NUM> may be embedded in the same plastic material in the same molding cycle as the slats <NUM>. The plastic material may be a rigid or semi-rigid plastic material comprising a thermoplastic material (e.g., ABS, PC/ABS, PP, nylon, polyester, etc.) and may additionally include fillers (e.g., glass fibers, mineral, etc.), impact modifiers, and/or other additives.

Each slat <NUM> has opposite first and second ends <NUM>, <NUM> with a central portion <NUM> extending between its opposite ends. The plastic material in which the cord <NUM> is embedded may extend continuously from one end <NUM> to the other end <NUM> along the entire central portion <NUM> of each slat. The opposite transverse ends <NUM>, <NUM> of the door may thus be at least partially defined by the opposite ends <NUM>, <NUM> of the plurality of slats <NUM>. Other plastic materials are not excluded from use as part of the substrate <NUM>.

The unidirectional cord <NUM> may extend the full length of the substrate <NUM> and may be embedded in the plastic material of every one of the plurality of slats <NUM> as shown. In this example, the cord <NUM> is embedded in the handle portion <NUM> of the substrate <NUM> as well. The cord <NUM> functions to interconnect all of the slats <NUM> of the substrate <NUM> in a mutually parallel arrangement. The slats <NUM> are spaced apart in the longitudinal direction and along the movement direction A such that, in the absence of the overlying decorative layer <NUM>, the cord or cords <NUM> are the only element holding the slats <NUM> together in the desired spatial relationship. As used herein, "unidirectional" means only in the direction of door movement, which is a linear direction that may be rectilinear and/or curvilinear. As noted above, the direction of movement A is defined by the end guides <NUM>, <NUM> of the support assembly <NUM>. When the substrate <NUM> is laid flat as in <FIG>, the cord <NUM> lies in a horizontal (x-y) plane. Unidirectional also means that the cord is not woven under some slats and under other slats.

The cord <NUM> can be formed from any material sufficiently strong to hold the slats <NUM> together in the absence of the decorative layer <NUM> or other overlying or underlying layers. Where the cord is molded-in to the plastic material of the slats <NUM>, the cord <NUM> may also be selected to withstand the temperatures and pressures encountered during the molding process. In the illustrated example, the substrate <NUM> includes two cords <NUM> running parallel with each other. More or less cords may be used. In one embodiment, each cord <NUM> is a length of yarn, where a yarn is a bundle of individual strands of material. The strands of the yarn may be woven, braided, twisted, or otherwise bonded with one another, with the cross-sectional size of the yarn being larger than that of a single strand. In other embodiments, each cord <NUM> is a single strand of material. Yarns may be preferred due to their inherent flexibility, which helps facilitate the cord's function as an articulated joint between slats <NUM>. Yarns may also be preferred when the cord <NUM> is molded into the slats <NUM> due to the ability of the interstitial spaces between strands to permit the overmolding material to infuse or at least partially penetrate the yarn for better cord-to-slat bonding. The cord <NUM> may alternatively have a flat ribbon-like configuration with the opposite flat surfaces of the ribbon facing toward and away from the decorative layer <NUM> of the finished door <NUM>.

In some embodiments, each cord <NUM> comprises synthetic fibers or consists essentially of synthetic fibers. Each cord <NUM> may for example be formed from a nylon, polyester, or UHMWPE thread (e.g., Dyneema® thread). Where the cord <NUM> is molded-in to the slats <NUM> in an overmolding process, the cord material may be synthetic and selected to have a higher melting point (Tm) and/or (Tg) than the overmolded plastic material. In one particular example, each cord comprises or consists essentially of aramid fibers (e.g., Kevlar®). In another embodiment, the cord includes or consists essentially of a Aramid fibers have been found to suitably withstand the temperatures involved in plastic molding processes (i.e., the fibers do not melt) while also withstanding the pressures involved in injection molding processes. For instance, aramid fibers may maintain their initial position during the molding process due to their strength and due to their high temperature strength-i.e., the molten plastic overmolding material does not substantially soften the aramid fibers during a molding process such that an aramid yarn can be placed in a mold cavity under tension and kept relatively stationary within the cavity even when surrounded by molten molding material and when oriented across a flow direction of the molten molding material.

Other types of materials, fibers, strands, and yarns may also be suitable, depending somewhat on the type of overmolding material being used. Each cord <NUM> may be formed from a multi-strand continuous fiber material, where the fibers include aramid fibers, glass fibers, carbon fibers, metal (e.g., stainless or coated steel) fibers, nylon fibers, and/or other suitable fibers. Another consideration is the coefficient of linear thermal expansion of the cord material, where a lower CLTE is generally better. In various embodiments, the cord <NUM> comprises fibers having a CLTE of ±<NUM> x <NUM>-<NUM> per °F or less, and preferably less than ±<NUM> x <NUM>-<NUM> per °F. A lower CLTE helps with dimensional stability of the cord <NUM> during the rapid heating and subsequent cooling involved in an overmolding process. Where the cord <NUM> is a yarn, it may be a <NUM>-denier yarn, a <NUM>-denier yarn, a <NUM>-denier yarn, or another suitable yarn fineness. The cord <NUM> may further include an anti-static lubricant along its circumference or along the individual strands of a yarn.

<FIG> is a cross-sectional view of a portion of the tambour door substrate <NUM> of <FIG>, taken along one of the unidirectional cords <NUM>. As illustrated, the plastic material of each slat <NUM> may entirely surround the cord. Stated differently, wherever the cord <NUM> is embedded in the plastic material of a slat <NUM>, that plastic material is present around the entire perimeter or cross-sectional circumference of the cord. In the illustrated example, the cord <NUM> is located within the thickness T of each slat <NUM> about midway between the opposite top and bottom sides of the slats. In other embodiments, the cord <NUM> may be offset toward the bottom sides of the slats <NUM>. The thickness T of each slat <NUM> may be in a nonlimiting range from <NUM> millimeters to <NUM> millimeters, more preferably from <NUM> millimeters to <NUM> millimeters. In a specific embodiment, the thickness T of each slat <NUM> is in a range from <NUM> millimeters to <NUM> millimeters, or from <NUM> millimeters to <NUM> millimeters. The cord <NUM> may have a diameter or average cross-sectional dimension in a range from <NUM> millimeters to <NUM> millimeters, or <NUM> millimeters to <NUM> millimeters. Smaller is generally better from a cord material cost perspective and for flexibility in the articulated joints of the substrate <NUM>. However, a larger cord diameter may be necessary for prevention of movement of the cord <NUM> during overmolding.

The slats <NUM> are spaced apart in the direction of movement A of the door <NUM>, and the spacing D between adjacent slats <NUM> may be in a range from <NUM> millimeter to <NUM> millimeters, or from <NUM> millimeter to <NUM> millimeters. In a specific embodiment, the spacing D between adjacent slats <NUM> is in a range from <NUM> millimeters to <NUM> millimeters, or about <NUM> millimeters. A width W of each slat <NUM> may be less than or equal to the thickness T of each slat. Each slat <NUM> may have the same length L, thickness T, width W, and distance D between itself and an adjacent slat. The slats <NUM> may be spaced apart, as shown, such that one slat is not connected to an adjacent slat by the same plastic material in which the cord <NUM> is embedded and/or such that none of the slats are connected to adjacent slats by the same plastic material in which the cord is embedded. The plastic material of the slats <NUM> may be the only plastic material of the substrate <NUM> (excluding polymeric cord materials) such that one slat is not connected to an adjacent slat by the any molded material and/or such that none of the slats are connected to adjacent slats by any molded material.

<FIG> schematically illustrate at least a portion of a method of making the above-described tambour door <NUM>. These figures show formation of a version of the tambour door substrate <NUM> with a smaller number of slats <NUM> than in <FIG>. <FIG> illustrate portions of a slat molding tool <NUM>, which is simplified here for illustrative purposes. Skilled artisans will recognize that the molding tool <NUM> may include several non-illustrated features, such as ejector pins, cooling lines, a hot runner system, injection ports, etc. The method may include first supporting the unidirectional cord <NUM> between opposing first and second portions <NUM>, <NUM> of the slat molding tool <NUM> while the molding tool is in an open condition, as shown in <FIG>, which is a cross-sectional view taken along a plane passing through the length of the cord <NUM> similar to that of <FIG>. Each portion <NUM>, <NUM> of the tool <NUM> includes recesses <NUM> corresponding in location with the slats <NUM> of the finished substrate <NUM>.

<FIG> is a cross-sectional view of the same molding tool <NUM> taken through recesses <NUM> of the molding tool. As shown here, one or both portions <NUM>, <NUM> of the tool <NUM> may include recesses or clearance features <NUM> to accommodate the cord(s) <NUM> so that, when the opposite portions <NUM>, <NUM> of the tool are moved toward each other to place the tool in a closed condition, as in corresponding <FIG>, the cord <NUM> is not subjected to the full clamp load C of the molding press in which the molding tool <NUM> is mounted. Preferably, the recesses <NUM> are sized such that the cord <NUM> is subjected to little or none of the clamp load C, for example less than <NUM>%, less than <NUM>%, less than <NUM>%, or substantially none of the clamp load C. In this manner, the cord <NUM> is not cut into pieces by the closing molding tool so that it can maintain its position during material injection.

As shown in <FIG>, the cord <NUM> may be placed in tension under a tensile load (F) before the tool <NUM> is changed to the closed condition. This tension can help stabilize the position of the cord in the tool <NUM> during molding.

<FIG> are respectively the same cross-sectional views of <FIG> after the tool <NUM> has been changed from the open condition to the closed condition. The recesses <NUM> of the first and second portions <NUM>, <NUM> of the tool combine to form a mold cavity <NUM> when the tool is in the closed condition. While not shown here, the cavity may include a runner system with branches connecting one or more injection ports of the molding tool <NUM> to the portions of the cavity <NUM> that form the slats <NUM> of the substrate <NUM>. The runner system may be located at ends of the cavity <NUM> corresponding to ends <NUM>, <NUM> of the slats <NUM>, for example.

Molten plastic material <NUM>' is then introduced into the cavity <NUM>, by injection, for example, as shown in <FIG>. The plastic material is then allowed to cool and solidify into the slats <NUM> of the substrate <NUM> as in <FIG>, after which the tool <NUM> is returned to the open condition of <FIG> for removal of the molded tambour door substrate. Solidified plastic material from any runner system may be removed at this time, and excess cord extending beyond the full length of the substrate <NUM> may also be trimmed away.

Processes other than thermoplastic injection molding may be suitable to embed the cord <NUM> in the plastic material, such as reaction injection molding, transfer molding, compression molding, or thermoforming, which may also be considered a molding process.

It is to be understood that the foregoing is a description of one or more embodiments of the invention. The invention is not limited to the particular embodiment(s) disclosed herein, but rather is defined solely by the claims below. Furthermore, the statements contained in the foregoing description relate to particular embodiments and are not to be construed as limitations on the scope of the invention or on the definition of terms used in the claims, except where a term or phrase is expressly defined above. Various other embodiments and various changes and modifications to the disclosed embodiment(s) will become apparent to those skilled in the art. All such other embodiments, changes, and modifications are intended to come within the scope of the appended claims.

Claim 1:
A vehicle interior assembly (<NUM>) comprising a tambour door (<NUM>) that is moveable along end guides (<NUM>, <NUM>) of the assembly (<NUM>) between an open position and a closed position, characterized in that the tambour door (<NUM>) comprises a plurality of slats (<NUM>) interconnected by a unidirectional cord (<NUM>) embedded in a plastic material of each one of the slats (<NUM>), wherein the cord (<NUM>) is molded-in to each one of the slats (<NUM>).