AUTOMOTIVE INTERIOR COMPONENT WITH CANTILEVERED SKIN PORTION AND METHOD OF MAKING THE SAME

• US 20090246505A1
• Filed: 03/23/2009
• Published: 10/01/2009
• Est. Priority Date: 03/26/2008
• Status: Abandoned Application

• Current Assignee: Intertec Systems LLC
• Original Assignee: Intertec Systems LLC
• Inventors: Barney, Chris, Evans, Gregg S.
• Application Number:
  US12/409,248
• Publication Number:
  US 20090246505A1
• Time in Patent Office: Days
• US Class Current: 428/316.600
• CPC Class Codes: B29C 44/1228 Joining preformed parts by the expanding material
• CPC Class Codes: B32B 2266/0278 Polyurethane
• CPC Class Codes: B32B 2270/00 Resin or rubber layer containing a blend of at least two different polymers
• CPC Class Codes: B32B 2307/546 Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2605/003 Interior finishings
• CPC Class Codes: B32B 27/065 of foam
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/365 comprising polycarbonates
• CPC Class Codes: B32B 27/40 comprising polyurethanes
• CPC Class Codes: B32B 3/04 characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
• CPC Class Codes: B32B 5/20 foamed in situ
• CPC Class Codes: B32B 7/05 the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection using interposed adhesives or bonding materials applied in spaced arrangements B32B7/14
• CPC Class Codes: B60Q 3/12 lighting onto the surface to be illuminated
• 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 13/0256 Dashboard liners
• CPC Class Codes: B60R 13/0262 Mid-console liners
• CPC Class Codes: B60R 2013/0287 integrating other functions or accessories
• CPC Class Codes: Y10T 428/249981 Plural void-containing components

Abstract

The invention provides for a multi-layer automotive interior component and method of making the same. The multi-layer automotive interior component comprises a skin layer having an exterior portion and an underside portion, where the exterior portion is visible. The multi-layer automotive interior component further comprises a foam dam formed on the underside portion of the skin layer, a cantilevered skin portion extending from the foam dam, a substrate disposed opposite the underside portion of the skin layer, and a foam layer between the substrate and the underside portion of the skin layer. The foam layer is limited by the foam dam, and the foam layer is substantially uniform.

Claims

1. A multi-layer automotive interior component comprising:

a skin layer having an exterior portion and an underside portion, the exterior portion being visible;

a foam dam formed on the underside portion of the skin layer;

a cantilevered skin portion extending from the foam dam;

a substrate disposed opposite the underside portion of the skin layer; and

,

a foam layer between the substrate and the underside portion of the skin layer, wherein the foam layer is limited by the foam dam, and further wherein the foam layer is substantially uniform.

2. The multi-layer automotive interior component of claim 1, further comprising a light source coupled to the cantilevered skin portion.

3. The multi-layer automotive interior component of claim 1, further comprising a light source coupled to the foam dam.

4. The multi-layer automotive interior component of claim 1, wherein the multi-layer automotive interior component is made by a reaction injection molding (RIM) process.

5. The multi-layer automotive interior component of claim 1, wherein the cantilevered skin portion is not in contact with the foam layer.

6. The multi-layer automotive interior component of claim 1, wherein the cantilevered skin portion forms an angle of between about 30 degrees to about 120 degrees with the foam dam.

7. An automotive instrument panel comprising:

a skin layer having a first side, a second side, and an edge, the first side being visible, the second side being substantially free of an extraneous flash material, and the edge being configured to align with a different automotive interior component;

a substantially uniform foam layer disposed adjacent the second side;

a foam dam formed on the second side of the skin layer near the edge, wherein the foam dam limits the foam layer; and

,

a cantilevered skin portion extending from the foam dam, wherein the cantilevered skin portion is not in contact with the foam layer.

8. The automotive instrument panel of claim 7, further comprising a light source adjacent the cantilevered skin portion, wherein the light source is below the first side of the skin layer and provides light to the automotive interior component.

9. The automotive instrument panel of claim 7, further comprising a light source adjacent the foam dam, wherein the light source is below the first side of the skin layer and provides light to the automotive interior component.

10. The automotive instrument panel of claim 7, wherein the foam layer is substantially free of disruption from the extraneous flash material on the second side of the skin layer.

11. A method of making a multi-layer automotive interior component comprising:

manufacturing a skin layer having a foam dam and a cantilevered skin portion;

positioning the skin layer adjacent a substrate;

injecting a foam layer between the skin layer and the substrate, wherein the foam layer flows substantially free of disruption between the substrate and the skin layer and the foam layer is limited by the foam dam, and wherein the foam layer then hardens and fixedly joins the skin layer to the substrate.

12. The method of claim 11, wherein the manufacturing step comprises reaction injection molding.

13. The method of claim 12, wherein the reaction injection molding comprises using a core for forming the skin layer, the core having a complementary cavity for forming the foam dam.

14. The method of claim 13, wherein use of the core does not produce an extraneous flash material on an underside portion of the skin layer.

15. The method of claim 12, wherein the reaction injection molding comprises using a first core being either rotatable or slidable for forming a first side of the foam dam, and a second core being slidable for forming a second side of the foam dam and an underside portion of the skin layer.

16. The method of claim 11, wherein the cantilevered skin portion is coupled to a light source.

17. The method of claim 11, wherein the foam dam is coupled to a light source.

18. A method of making an automotive instrument panel comprising:

manufacturing a skin layer having a first side, a second side, an edge, a foam dam, and a cantilevered skin portion, wherein the first side is visible, the second side is substantially free of an extraneous flash material, and the edge is configured to align with a different automotive interior component;

positioning the skin layer adjacent a substrate; and

,

injecting a foam layer between the skin layer and the substrate, wherein the foam layer flows substantially free of disruption between the substrate and the skin layer and the foam layer is limited by the foam dam, and wherein the foam layer then hardens and fixedly joins the skin layer to the substrate.

19. The method of claim 18, wherein the cantilevered skin portion is coupled to a light source.

20. The method of claim 18, wherein the foam dam is coupled to a light source.