Vehicle interior trim panel component assembly and in-mold method of manufacturing same
First Claim
1. A method of manufacturing a trim panel assembly for the interior of a vehicle having integrated trim panel components, said method comprising the steps of:
- providing a die including a pair of die halves cooperating to define a mold cavity to form a interior trim panel, at least one of said die halves including a surface within said mold cavity defining an A-surface, one of said mold cavities including a plurality of recesses having a predetermined shape;
placing at least one trim panel component into said corresponding recess within said mold cavity;
closing said first and said second die halves;
forming a rigid substrate having an A-side surface visible to the interior of a vehicle when secured to a vehicle door in said mold cavity by injecting a molten thermoplastic material having a predetermined pressure less than the maximum clamp pressure of said die into said mold cavity so as to fill said mold cavity; and
bonding said molten thermoplastic material to at least one trim panel component within said mold cavity while said rigid substrate is formed.
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Accused Products
Abstract
The present invention relates to a method of manufacturing an interior trim panel assembly having integrated trim panel components. The method of manufacture includes providing a die including a pair of die halves cooperating to define a mold cavity to form a interior trim panel where at least one of said die halves includes a surface defining an A-surface and the mold cavity includes a plurality of recesses. The method further includes placing a trim panel component into a recess and closing the die halves to form a rigid substrate within the mold cavity by injecting a molten thermoplastic material into the mold cavity mold cavity. The method further includes bonding the molten thermoplastic material to a trim panel component within the mold cavity while the rigid substrate is formed.
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Citations
19 Claims
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1. A method of manufacturing a trim panel assembly for the interior of a vehicle having integrated trim panel components, said method comprising the steps of:
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providing a die including a pair of die halves cooperating to define a mold cavity to form a interior trim panel, at least one of said die halves including a surface within said mold cavity defining an A-surface, one of said mold cavities including a plurality of recesses having a predetermined shape;
placing at least one trim panel component into said corresponding recess within said mold cavity;
closing said first and said second die halves;
forming a rigid substrate having an A-side surface visible to the interior of a vehicle when secured to a vehicle door in said mold cavity by injecting a molten thermoplastic material having a predetermined pressure less than the maximum clamp pressure of said die into said mold cavity so as to fill said mold cavity; and
bonding said molten thermoplastic material to at least one trim panel component within said mold cavity while said rigid substrate is formed. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A trim panel assembly for the interior of a vehicle having integrated trim panel components comprising:
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at least one trim panel component adapted for placement in a mold cavity, said trim panel component adapted for use vehicle trim panel applications having at least one surface visible from a vehicle interior;
a substrate adapted for use as a vehicle interior door trim panel formed from injection of a rigid forming polymer into a mold wherein said formed substrate operatively engages said trim panel component, said substrate having a first side and a second side opposite said first side, said first side defining a A-side surface exposed to the vehicle interior when secured to a vehicle door, said second side defining a B-side surface concealed from the vehicle interior when secured to a vehicle door. - View Dependent Claims (10, 11, 12, 13, 14, 15, 16, 17, 18, 19)
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Specification