Method of making an interior trim part and article made by the process

• US 20040191477A1
• Filed: 03/24/2003
• Published: 09/30/2004
• Est. Priority Date: 03/24/2003
• Status: Abandoned Application

• Current Assignee: Lear Corporation
• Original Assignee: Lear Corporation
• Inventors: Peak, Timothy L., Mikhjian, Sarkis B., Davis, Joseph J. Jr.
• Application Number:
  US10/396,875
• Publication Number:
  US 20040191477A1
• Time in Patent Office: Days
• US Class Current: 428/141
• CPC Class Codes: B29C 2791/001 Shaping in several steps
• CPC Class Codes: B29C 37/0032 the coating being applied upon the mould surface before introducing the moulding compound, e.g. applying a gelcoat B29C44/14 and B29C44/32 take precedence
• CPC Class Codes: B29C 37/0053 Moulding articles characterised by the shape of the surface, e.g. ribs, high polish mould construction therefor B29C33/42; surface shaping of articles B29C59/00; by incorporating filler in or near the surface B29C70/64
• CPC Class Codes: B29C 41/08 Coating a former, core or other substrate by spraying or fluidisation, e.g. spraying powder spray-up of reinforcing fibres B29C70/305
• CPC Class Codes: B29C 44/146 Shaping the lining before foaming
• CPC Class Codes: B29C 44/148 Applying the foaming resin, moulding the lining or the like, with the lining turned inside out
• CPC Class Codes: B29K 2105/04 cellular or porous
• CPC Class Codes: B29K 2105/243 Partially cured
• CPC Class Codes: B29L 2031/3005 Body finishings
• CPC Class Codes: Y10T 428/24355 Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]

Abstract

A method of making a skin of an interior trim part and an interior trim part made according to the process. A male mold having a convex portion is used to form a skin having a uniform thickness that is sprayed on the surface of the mold. The surface of the mold has a grain pattern that is transferred to a skin. The skin is allowed to flash off or partially cure before being removed from the male mold. The skin is then turned inside out with the exterior surface being inverted to form a convex portion of the skin. The skin is placed into a female mold having a concave portion against which the convex portion of the skin is placed. Foam is injected into the inverted skin while in a female mold and is cured to form an interior trim part.

Claims

1. A method of making an interior trim part for a vehicle, the interior trim part having a skin defining an exterior surface of the interior trim part having a predefined shape comprising:

providing a first mold having a mold surface having a convex portion;

spraying a polymeric material onto the mold surface to form the skin with an exterior surface being formed on a concave portion of the skin;

waiting a period of time to allow the skin formed by the polymeric material to be at least partially cured;

removing the skin from the first mold;

turning the skin inside out with the exterior surface being inverted to form a convex portion of the skin;

placing the skin into a second mold having a concave portion that the convex portion of the skin is placed against;

injecting foam into the skin while disposed in the concave portion of the second mold; and

curing the foam to form the interior trim part with the exterior surface of the skin covering the interior trim part.

2. The method of claim 1 wherein the first mold surface is provided with a grain pattern that is transferred to the exterior surface of the skin.

3. The method of claim 1 wherein the polymeric material is a urethane mixture.

4. The method of claim 1 wherein the polymeric material is polyvinylchloride.

5. The method of claim 1 wherein the convex portion of the first mold surface is a mirror image of the predefined shape and the concave portion of the second mold corresponds to the predefined shape.

6. The method of claim 1 wherein the polymeric material is sprayed onto the mold surface with a uniform thickness over the convex portion.

7. An interior trim component for a vehicle that is made according to a process, wherein the trim component comprises:

an elastomeric skin formed on a first mold surface having a convex portion that is formed initially on a skin forming mold;

a urethane foam injected to fill a cavity defined within the skin, the skin being turned inside out after being formed on the convex portion of the skin forming mold prior to being filled with a foam.

8. The interior trim of claim 7 wherein the elastomeric skin has a grain pattern that is formed on a concave portion of the skin when the skin is formed on the convex portion of the first mold, the grain pattern being on a convex portion of the interior trim component after the skin is turned inside out and filled with foam.

9. The interior trim component of claim 7 wherein the elastomeric skin is a urethane mixture.

10. The interior trim component of claim 7 wherein the elastomeric skin is a polyvinylchloride mixture.

11. The interior trim component of claim 7 wherein the convex portion of the interior trim component defines a brow area of an instrument panel having a sharper radius than a less contoured portion of the instrument panel and wherein the thickness of the skin in the brow area is the same as the thickness of the skin in the less contoured portion of the instrument panel.

12. A method of making a skin of an interior trim part for a vehicle, the skin defining an exterior surface of the interior trim part having a predefined shape comprising:

providing a male mold having a mold surface defining an essentially convex portion;

spraying a polymeric material onto the mold surface to form the skin with an exterior surface being formed on a concave portion of the skin;

waiting for the skin formed by the polymeric material to at least partially cure;

removing the skin from the mold; and

turning the skin inside out with the exterior surface being inverted to form a convex portion of the skin.

13. The method of claim 12 wherein the male mold surface is provided with a grain pattern that is transferred to the exterior surface of the skin.

14. The method of claim 12 wherein the polymeric material is a urethane mixture.

15. The method of claim 12 wherein the polymeric material is polyvinylchloride.

16. The method of claim 12 wherein the convex portion of the male mold surface is a mirror image of the predefined shape and the concave portion of the female mold corresponds to the predefined shape.

17. The method of claim 12 wherein the polymeric material is sprayed onto the male mold surface with a uniform thickness over the convex portion.