AUTOMOTIVE BOLSTER WITH SOFT FEEL AND METHOD OF MAKING THE SAME

• US 20060279100A1
• Filed: 06/08/2005
• Published: 12/14/2006
• Est. Priority Date: 06/08/2005
• Status: Active Grant

• Current Assignee: International Automotive Components Group North America (Lear Corporation)
• Original Assignee: International Automotive Components Group North America (Lear Corporation)
• Inventors: Cowelchuk, Glenn A, DePue, Todd L, Dooley, David
• Granted Patent: US 7,284,784 B2
• Time in Patent Office: Days
• US Class Current: 296/39.100
• CPC Class Codes: B29C 45/045 mounted on the circumference of a rotating support having a rotating axis perpendicular to the mould opening, closing or clamping direction
• CPC Class Codes: B29C 45/1628 using a mould carrier rotatable about an axis perpendicular to the opening and closing axis of the moulding stations
• CPC Class Codes: B29C 45/1642 having a "sandwich" structure B29C45/1603 takes precedence
• CPC Class Codes: B29C 45/1676 using a soft material and a rigid material, e.g. making articles with a sealing part
• CPC Class Codes: B29K 2105/04 cellular or porous
• CPC Class Codes: B29L 2031/3005 Body finishings
• CPC Class Codes: B60R 13/02 Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners B60R13/01 takes precedence ; padded linings for the vehicle interior B60R21/04; arrangements or adaptations of floor mats or carpets in vehicles B60N3/04; internal lining for trains B61D17/18
• CPC Class Codes: B60R 13/0243 Doors
• CPC Class Codes: B60R 2013/0281 made of a plurality of visible parts

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.

Claims

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.

2. The method of claim 1, wherein at least one of the first and third materials is a foamed or blown thermoplastic polymer.

3. The method of claim 1, wherein at least one of the first and third materials includes recycled thermoplastic polymer.

4. The method of claim 1 wherein at least one of the second and fourth materials includes a colored thermoplastic polymer.

5. The method of claim 1, wherein the step of molding a substrate by co-injecting a first and second material comprises molding the substrate including at least one heat stake member by co-injecting the first and second material into the first shot mold cavity of the mold assembly in the first shot of the molding operation, the at least one heat stake member being formed from at least one of the first and second materials.

6. The method of claim 1, wherein the step of molding a substrate by co-injecting a first and second material comprises molding the substrate having at least one aperture therein, and wherein the step of integrally molding a cover to the substrate by co-injecting into the mold chamber a third and fourth material comprises integrally molding a cover to the substrate such that the integrally molded cover includes at least one aperture cooperating with the at least one aperture of the substrate for receiving a heat stake member therethrough.

7. The method of claim 1, wherein the step of providing a mold assembly having first and second shot mold cavities comprises providing a mold assembly having first and second shot mold cavities and a core having at least one male portion adapted to mate with each cavity, the core further being adapted to rotate;

wherein the step of molding a substrate comprises molding the substrate by mating the at least one male portion with the first shot mold cavity and co-injecting the first and second materials into the first shot mold cavity in the 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;

wherein the step of 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 comprises rotating the substrate on the at least one male portion of the core from the first mold cavity to the second mold cavity; and

wherein the step of forming a mold chamber comprises forming the mold chamber about the at least a portion of the substrate within the second shot mold cavity of the mold assembly by mating the at least one male portion with the second shot mold cavity to mold the cover in the second shot of the molding operation.

8. The method of claim 7, wherein the step of rotating the substrate comprises rotating the substrate about a horizontal axis to move the substrate from the first mold cavity to the second mold cavity.

9. A method of forming an automotive bolster with soft feel in a continuous two-shot molding operation, comprising:

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.

10. The method of claim 9, wherein at least one of the first and third materials is a foamed or blown thermoplastic polymer.

11. The method of claim 9, wherein at least one of the first and third materials includes recycled thermoplastic polymer.

12. The method of claim 9, wherein at least one of the second and fourth materials includes a colored thermoplastic polymer.

13. The method of claim 9, wherein the step of molding a substrate by co-injecting a first and second material comprises molding the substrate including at least one heat stake member by co-injecting the first and second material into the first shot mold cavity of the mold assembly in the first shot of the molding operation, the at least one heat stake member being formed from at least one of the first and second materials.

14. The method of claim 13, wherein the step of molding a substrate by co-injecting a first and second material comprises molding the substrate having at least one aperture therein, and wherein the step of integrally molding a cover to the substrate by co-injecting into the mold chamber a third and fourth material comprises integrally molding a cover to the substrate such that the integrally molded cover includes at least one aperture cooperating with the at least one aperture of the substrate for receiving a heat stake member therethrough.

15. An automotive bolster with soft feel, comprising:

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.

16. The automotive bolster of claim 15, wherein the substrate further includes at least one heat stake member adapted to secure the bolster to a trim panel, the at least one heat stake member being formed from at least one of the first and second materials.

17. The automotive bolster of claim 15, wherein the substrate further includes at least one aperture therein, and wherein the cover further includes at least one aperture cooperating with the at least one aperture of the substrate for receiving a heat stake member therethrough.

18. The automotive bolster of claim 15, wherein at least one of the first and third materials is a foamed or blown thermoplastic polymer.

19. The automotive bolster of claim 15, wherein at least one of the first and third materials includes recycled thermoplastic polymer.

20. The automotive bolster of claim 15, wherein at least one of the second and fourth materials includes a colored thermoplastic polymer.