Note: Descriptions are shown in the official language in which they were submitted.
CA 02327707 2000-12-06
INTEGRATED SOFT PADS FOR ONE STEP MOLDED PARTS
BACKGROUND OF THE INVENTION
1. Field of the Invention
The subject invention relates to a process for forming softly padded areas
within a
molded armrest of an interior door panel.
2. Description of the Related Art
By way of background, molded vehicle components, such as armrests, are known
in
the art and very common to automotive interior panels, such as door panels.
Typically, an
automotive armrest includes portions which are padded for comfortable support
of a person's
arm or hand. Most often, increased padding is achieved by applying foam
backing to the
inner surface of the armrest covering. This method does not allow for
localization, and
increases the cost due to extra foam backing applied where padding is not
needed.
For example, U.S. Patent nos. 5,885,662; 6,013,210; and 6,017,617 disclose an
interior panel, such as an interior door panel having an armrest, and process
for making the
same. The interior panel is manufactured by molding a composite structure of
an inner layer
chemically bonded to an outer layer. A polyurethane cellular foam filler is
sprayed onto the
composite structure and then a preformed rigid substrate is applied against
the cellular foam
filler to provide reinforcing strength and support to the inner and outer
layers. The
polyurethane cellular foam serves to unite the layered composite structure
with the preformed
rigid substrate.
Alternatively, localized padding can be achieved by applying a foam layer to
the
inner surface of the armrest covering and increasing the thickness of the foam
layer at the
point where increased localized padding is desired or inserting a foam pad of
specific
hardness-softness characteristics against the outer cover of the armrest. Such
methods are
exemplified in U.S. Patent nos. 4,869,543 and 5,387,390. To achieve this,
specially
manufactured pieces and additional processing steps must be utilized, which
also add
processing time and costs.
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SUMMARY OF THE INVENTION
The disadvantages of the prior art may be overcome by providing a process for
making an interior vehicle component having localized padding.
According to one aspect of the invention, there is provided a process for
making a
padded part for an interior of an automobile. The process includes the steps
of providing an
outer cover on a contoured mold. Placing a blocking device against a portion
of an inside
surface of the outer cover. Forming a substrate against the inside of the
outer cover and
about the blocking device. Providing a support structure for the outer cover.
Removing the
blocking device to form a cavity in the substrate and providing a resilient
filler material
within the cavity to give local padded support to the outer cover.
BRIEF DESCRIPTION OF THE DRAWINGS
Advantages of the present invention will be readily appreciated as the same
becomes
better understood by reference to the following detailed description when
considered in
connection with the accompanying drawings wherein:
Figure 1 is partially sectioned perspective view of a vehicle interior door
panel and
armrest constructed in accordance with the present invention;
Figure 2 is a cross-sectional view of the armrest portion of the door panel of
Figure
1 including a cavity formed by the present invention for receiving a pad of
filler material;
Figure 3 is a cross-sectional view of the armrest portion including the pad of
filler
material inserted within the cavity;
Figure 4 is a cross-sectional view of a mold for forming the interior door
panel;
Figure 5 is a cross-sectional view of the mold supporting a contoured outer
cover of
the door panel;
Figure 6 is a cross-sectional view of the mold having a substrate formed
against the
outer cover and about the blocking device inserted in the mold for forming the
cavity in the
armrest;
Figure 7 is cross-sectional view of the mold with the blocking device removed
from
the cavity and a pad of filler material inserted or formed with the cavity.
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Refernng to the Figures, wherein like numerals indicate like or corresponding
parts
throughout the several views, an interior component, such as a interior door
panel, for an
automotive vehicle is generally shown at 10 in Figure 1. The panel 10 includes
a generally
planar door covering portion 12 and an armrest portion 14, or padded part, for
supporting the
arm or hand of an occupant of the vehicle. As shown in the cross-section
portion of Figure
1, the panel 10 includes an outer cover 16 having an exterior surface 18
exposed or facing
the interior of the vehicle and an interior surface 20 which is hidden from
the interior of the
vehicle. The panel 10 further includes a rigid, or semi-rigid, substrate 22 to
provide
structural support for the outer cover 16. The armrest portion 14 includes a
cavity 24 for
receiving a resilient pad 26 of filler material, such as urethane foam, a pre-
formed foam bun,
or liquid foam-in-place urethane material, to provide a soft padded backing to
a portion of
the outer cover 16 defined by the cavity 24 of the armrest portion 14. The
substrate 22 is
typically molded or adhered to the interior surface 20 of the outer cover 16
to provide
structural shape and padded support to the outer cover 16. However, the
substrate 22 does
not extend over the portion of the outer cover 16 defining the cavity 24. The
substrate 14
may include a rib 28, or plurality of ribs, to provide extra support and to
further define the
cavity 24.
Refernng to Figures 2 and 3, the cavity 24 is formed by a portion of the outer
cover
16 in the armrest portion 14. The cavity 24 may be further defined between a
generally
horizontal portion 30 of the outer cover 16 defining the top support surface
of the armrest 14
and the generally horizontal rib 28 which is generally parallel to and spaced
from the
horizontal portion 30. However, the cavity 24 may also be formed entirely by a
portion of
the outer cover 16. As shown in Figure 3, when a foam or liquid filler
material forming the
resilient pad 26 is received within the cavity 24, the foam or liquid filler
material will provide
a support backing for the portion of the outer cover 16 over the cavity 24,
thereby providing
a soft padded support area on the armrest portion 14. The softness of the
armrest portion 14
is dependant upon the type of filler material used for the resilient pad 26.
That is, different
types of foam, gel, or liquid may be used as are commonly known to those
skilled in the art.
Further, an insert can be molded as a preformed resilient pad 26 to fit within
the cavity 24,
made from foam or other suitable material, and may be held within the cavity
24 by adhesive.
Refernng to Figures 4-7, the present invention relates to a process for making
the
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panel 10 and padded armrest portion 14 including the cavity 24 immediately
below the outer
cover 16 for localized padded support within the armrest portion 14 including
the step of
placing the outer cover 16 onto a contoured surface 32 of a mold 34 and
conforming the outer
cover 16 to the contours of the contoured surface 32 of the mold 34. The outer
cover 16 may
be a sheet of material such as vinyl, leather, cloth, plastic or blend
thereof, as is commonly
known to one skilled in the art. The mold 34 may include a vacuum mold for
providing
vacuum pressure to assist the outer cover 16 to fully conform to the mold
surface 32 and hold
the cover 16 against the mold surface 32 as is commonly known to one skilled
in the art.
Optionally, the outer cover 16 may be formed directly onto the contoured
surface 32
of mold 34 by spraying a reaction mixture of a cover material comprising
polyurethane and
then polyol and polyisocyanate as more fully described in United States Patent
nos.
5,885,662; 6,013,210; and 6,017,617. Alternatively, the outer cover 16 may be
formed on
a similarly contoured mold and then transferred to the mold 34.
The process further includes placing a blocking device 36 in the mold 34 along
a
portion of the interior surface 20 of the outer cover 16 at a localized
position in the mold 34
adjacent to a portion of the outer cover 16. The blocking device 36 may
include a pre-formed
and pre-shaped block of plastic, metal, wood or other material, provided that
the blocking
device does not permanently bond or adhere to the substrate 22 or the outer
cover 16.
Optionally, a release agent could be pre-applied to the blocking device 36
prior to
presentation to facilitate release.
The blocking device 36 may be a separate component which is manipulated in
place
by a robot as is well known in the art. Alternatively, blocking device 36 may
be incorporated
into an upper mold. The method of applying the rigid substrate 22 will
determine which
method is the most suitable.
The substrate 22 is then formed against the interior surface 20 of the outer
cover 16
and about, or around, the blocking device 36, providing a support structure
for the outer
cover 16. The blocking device 36 is then removed from the mold 34, forming the
cavity 24
in the substrate 22 for receiving the filler material defining the resilient
pad 26. The filler
material defining the resilient pad 26 is applied within the cavity 24 to give
localized padded
support to the outer cover 16 and armrest portion 14. The resilient pad 26 may
be applied
within the cavity 24 by application of inserting a pre-formed foam pad into
the cavity 24,
pouring or spraying a liquid foam or gel into the cavity 24, or other suitable
applications.
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The substrate 22 in the preferred embodiment may be formed against the
interior
surface 20 and around the blocking device 36 by pouring or spraying a liquid
material, such
as plastic, urethane, polyurethane, or the like, to cure as the substrate 22
within the mold 34.
Alternatively, the substrate 22 may be a pre-formed substrate 22 applied
against the interior
surface 20 of the outer cover 16 and attached thereto by adhesive or other
means.
The invention has been described in an illustrative manner, and it is to be
understood
that the terminology which has been used is intended to be in the nature of
words of
description rather than of limitation. Many modifications and variations of
the present
invention are possible in light of the above teachings. It is, therefore, to
be understood that
within the invention may be practiced otherwise than as specifically
described.
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