AUTOMOTIVE BOLSTER WITH SOFT FEEL AND METHOD OF MAKING THE SAME
First Claim
1. A method of forming an automotive bolster with soft feel in a continuous two-shot molding operation, comprising:
- providing a mold assembly having first and second shot mold cavities;
molding a substrate by co-injecting a first and second material into the first shot mold cavity of the mold assembly in a first shot of the molding operation, the second material being different than the first material and forming an outer skin layer which surrounds the first material;
moving the substrate from the first shot mold cavity to the second shot mold cavity by using at least a portion of the mold assembly;
forming a mold chamber about at least a portion of the substrate within the second shot mold cavity of the mold assembly; and
integrally molding a cover to the substrate by co-injecting into the mold chamber a third and fourth material in a second shot of the molding operation, the fourth material being different than the third material and forming an outer skin layer which surrounds the third material, wherein at least one of the materials provides the bolster with a soft feel.
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Accused Products
Abstract
The present invention provides for an improved bolster with a soft feel for use in a trim assembly, and to a continuous two-shot molding operation that may be continuously performed utilizing a single mold assembly. In an exemplary embodiment, the bolster includes a substrate formed by co-injecting a first and second material into a first shot mold cavity in a first shot of a molding operation. In a second shot mold cavity, a cover is formed on at least a portion of the substrate by co-injecting into a mold chamber a third and fourth material in a second shot of the molding operation. The fourth material defines an outer skin surrounding the third material which may include a foamed material to provide a soft, light cellular inner core such that when a force is applied to the cover, the outer skin will deform and compress the inner core, providing a soft feel to the bolster.
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Citations
20 Claims
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1. A method of forming an automotive bolster with soft feel in a continuous two-shot molding operation, comprising:
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providing a mold assembly having first and second shot mold cavities;
molding a substrate by co-injecting a first and second material into the first shot mold cavity of the mold assembly in a first shot of the molding operation, the second material being different than the first material and forming an outer skin layer which surrounds the first material;
moving the substrate from the first shot mold cavity to the second shot mold cavity by using at least a portion of the mold assembly;
forming a mold chamber about at least a portion of the substrate within the second shot mold cavity of the mold assembly; and
integrally molding a cover to the substrate by co-injecting into the mold chamber a third and fourth material in a second shot of the molding operation, the fourth material being different than the third material and forming an outer skin layer which surrounds the third material, wherein at least one of the materials provides the bolster with a soft feel. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A method of forming an automotive bolster with soft feel in a continuous two-shot molding operation, comprising:
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molding a substrate by co-injecting a first and second material in a first shot of the molding operation, the second material being different than the first material and forming an outer skin layer which surrounds the first material;
forming a mold chamber about at least a portion of the substrate; and
integrally molding a cover to the substrate by co-injecting into the mold chamber a third and fourth material in a second shot of the molding operation, the fourth material being different than the third material and forming an outer skin layer which surrounds the third material, wherein at least one of the materials provides the bolster with a soft feel. - View Dependent Claims (10, 11, 12, 13, 14)
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15. An automotive bolster with soft feel, comprising:
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a substrate made from a first and second material, the second material being different than the first material and defining an outer skin layer which surrounds the first material; and
a cover made from a third and fourth material, the fourth material being different than the third material and defining an outer skin layer which surrounds the third material, the cover being integrally molded to at least a portion of the substrate, wherein at least one of the materials provides the bolster with a soft feel. - View Dependent Claims (16, 17, 18, 19, 20)
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Specification