Vehicle door trim bolster with multi-feel cover and method of making the same

• US 7,108,312 B2
• Filed: 11/09/2004
• Issued: 09/19/2006
• Est. Priority Date: 11/09/2004
• Status: Expired due to Fees

• Current Assignee: International Automotive Components Group North America (Lear Corporation)
• Original Assignee: Lear Corporation
• Inventors: Reed, Randy S, Cowelchuk, Glenn A, DePue, Todd L, Dooley, David, Hier, Michael J
• Primary Examiner(s): Patel, Kiran B.
• Application Number:
  US10/904,409
• Publication Number:
  US 20060097545A1
• Time in Patent Office: 679 Days
• Field of Search: 296/146.7, 296/153, 296/1.08, 297/411.21
• US Class Current: 296/146.7
• CPC Class Codes: B29C 44/086 and feeding more material into the enlarged cavity
• 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 2031/3026 Arm-rests
• CPC Class Codes: B60N 2/7017 characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for
• CPC Class Codes: B60N 2/78 post or panel mounted
• CPC Class Codes: B60R 21/04 Padded linings for the vehicle interior ; Energy absorbing structures associated with padded or non-padded linings
• CPC Class Codes: B60R 21/0428 associated with the side doors or panels, e.g. displaced towards the occupants in case of a side collision

Abstract

A door trim panel for a door frame of a motor vehicle. The door trim panel includes a main body portion adapted to be removably secured to the door frame and a bolster removably secured to the main body portion. The bolster covers an access opening in the main body portion. The bolster includes a substrate having a bolster portion integrally formed with an armrest portion. A cover is integrally molded with the substrate and includes a first portion overlying the bolster portion and having a first thickness, and a second portion overlying the armrest portion and having a second thickness greater than the first thickness to provide a softer feel. The bolster may be made in a two shot molding process with the substrate being formed in the first shot of the molding process and the multi-feel cover being formed in the second shot of the molding process.

Claims

1. A door trim panel for attachment to a door frame of a motor vehicle, comprising:

a main body portion adapted to be removably secured to the door frame, said main body portion including an access opening; and

a bolster removably secured to said main body portion, said bolster covering said access opening, said bolster comprising;

a substrate having a bolster portion integrally formed with an armrest portion and made from a first polymer material; and

a cover made from a second polymer material and integrally molded with said substrate, said cover having a first portion overlying said bolster portion of said substrate and having a first thickness, and a second portion overlying said armrest portion of said substrate and having a second thickness, said second thickness greater than said first thickness to provide a softer feel to said armrest portion.

2. The trim panel of claim 1, wherein said first portion of said cover being a substantially non-cellular structure, and said second portion of said cover including a cellular structure.

3. The trim panel of claim 1, wherein said first thickness is about 1–

3 mm and said second thickness is about 5–

12 mm.

4. The trim panel of claim 1, wherein said substrate includes a material selected from the group consisting of a polyolefin and polycarbonate/acrylonitrile butadiene styrene.

5. The trim panel of claim 1, wherein said cover includes a material selected from the group consisting of a thermoplastic elastomer and a polypropylene.