Integrated sunshade design

• US 8,663,535 B2
• Filed: 06/17/2011
• Issued: 03/04/2014
• Est. Priority Date: 06/17/2011
• Status: Expired due to Fees

• Current Assignee: Honda Motor Co., Ltd. (Honda Motor Company)
• Original Assignee: Honda Motor Co., Ltd. (Honda Motor Company)
• Inventors: Larcom, Ryan V., Large, Brian D., Canepa, Rachel E., Yamase, Shinichi
• Primary Examiner(s): SANDERS, JAMES M
• Application Number:
  US13/162,598
• Publication Number:
  US 20120319427A1
• Time in Patent Office: 991 Days
• Field of Search: 264/319, 264/328.1, 264/328.7
• US Class Current: 264/319
• CPC Class Codes: B29C 45/0053 combined with a final operation, e.g. shaping injection-compression moulding B29C45/561
• CPC Class Codes: B29C 45/376 adjustable B29C45/374 takes precedence
• CPC Class Codes: B29L 2031/3041 Trim panels
• CPC Class Codes: B60R 13/0243 Doors

Abstract

A trim panel for a door of a vehicle that wherein both sunshade and non-sunshade versions of the trim panel are manufactured on the same equipment, thus eliminating the need to prepare separate molds for each trim panel. Both the sunshade and non-sunshade versions of the trim panel share essentially the same components and dimension except that the sunshade trim panel has an upper surface that terminates prior to a corresponding surface of the non-sunshade trim panel. This feature allows both trim panels to be made on the same equipment and then installed as needed depending on whether a given door will include a sunshade assembly.

Claims

1. A method of making a trim panel for an automobile door including a sunshade, and a trim panel for an automobile door not including a sunshade, from the same molding equipment, the method comprising the steps of:

molding a non-sunshade trim panel using a plastic mold apparatus having a hydraulic slide in a retracted position, the first trim panel having a body with first and second ends, a door side surface extending between the first and second ends, and a door upper surface extending away from the door side surface;

advancing the hydraulic slide to an extended position for producing a sunshade trim panel;

molding a sunshade trim panel using the plastic mold apparatus with the hydraulic slide in the extended position, the sunshade trim panel having a body with first and second ends, a door side surface extending between the first and second ends, and a door upper surface extending away from the door side surface;

wherein the door upper panel of the non-sunshade trim panel extends further from the door side surface than does the door upper surface of the sunshade trim panel.

2. The method as set forth in claim 1, further comprising the step of applying a top coat to at least one of the non-sunshade trim panel and the sunshade trim panel using a vacuforming press.

3. The method as set forth in claim 2, further comprising using the same vacuforming press to apply the top coat to both the non-sunshade and sunshade trim panels.

4. The method as set forth in claim 2, further comprising the step of trimming a free end of the top coat and securing the free end of the top coat to the trim panel.

5. The method as set forth in claim 1, further comprising the step of selecting one of the sunshade trim panel or the non-sunshade trim panel for installation on a door of a vehicle based on whether a sunshade is to be installed in the door.

9. The method as set forth in claim 1, wherein the molding a non-sunshade trim panel and the molding a sunshade trim panel both include forming a heat stake for securing a weatherstrip thereto.

10. The method of claim 1, wherein the advancing the hydraulic slide includes terminating a mold chamber prematurely, whereby the areal extent of the door upper surface of the sunshade trim panel is reduced.

11. The method of claim 5, further comprising installing the selected one trim panel on a door of a vehicle.

6. A method of forming either a non-sunshade trim panel or a sunshade trim panel using the same equipment, both trim panels having a body with first and second ends, a door side surface extending between the first and second ends, and a door upper surface extending away from the door side surface, the door upper surface of the non-sunshade trim panel extending further from the door side surface than the door upper surface of the sunshade trim panel, the method comprising the steps of:

selecting either a non-sunshade trim panel or a sunshade trim panel for manufacture;

positioning a hydraulic slide of a molding press in a first or second position corresponding to the selected sunshade;

molding the selected sunshade;

applying a top coat to the molded sunshade using a vacuum form press, the vacuum form press adapted to apply a top coat to either of a non-shade trim panel or a sunshade trim panel;

trimming a free end of the top coat to a desired length; and

securing the free end of the top coat to the molded trim panel.

7. A method as set forth in claim 6, wherein the step of molding the selected sunshade includes molding using an injection molding machine.

8. A method as set forth in claim 6, wherein the step of applying the top coat includes applying a foam layer and a vinyl layer to the molded sunshade.

12. The method of claim 6, further comprising selecting one of the sunshade trim panel or the non-sunshade trim panel for installation on a door of a vehicle based on whether a sunshade is to be installed in the door.

13. The method of claim 12, further comprising installing the selected one trim panel on a door of a vehicle.