Automotive bolster with soft feel and method of making the same

• US 7,284,784 B2
• Filed: 06/08/2005
• Issued: 10/23/2007
• Est. Priority Date: 06/08/2005
• Status: Expired due to Fees

• Current Assignee: International Automotive Components Group North America (Lear Corporation)
• Original Assignee: Lear Corporation
• Inventors: Cowelchuk, Glenn A, DePue, Todd L, Dooley, David
• Primary Examiner(s): Dayoan; D. Glenn
• Assistant Examiner(s): CHENEVERT, PAUL A
• Application Number:
  US11/160,088
• Publication Number:
  US 20060279100A1
• Time in Patent Office: 867 Days
• Field of Search: 296/146.7, 296/152, 296/153, 264 451- 469, 264/255, 264/328.8, 525/11, 525/52, 527/165
• US Class Current: 296/153
• 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. 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 completely surrounds the first material, the substrate further including 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; 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.

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

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

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

5. 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, the substrate further including 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; 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 completely 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.

6. The automotive bolster of claim 5, wherein at least one of the first and third materials is a foamed or blown thermoplastic polymer.

7. The automotive bolster of claim 5, wherein at least one of the first and third materials includes recycled thermoplastic polymer.

8. The automotive bolster of claim 5, wherein at least one of the second and fourth materials includes a colored thermoplastic polymer.