Vehicle component and method for making a vehicle component
Abstract
A method for forming a component (210) for a vehicle includes providing a substrate (230) that includes a relatively rigid material and providing a skin (222) adjacent at least a portion of the substrate such that a cavity is formed between the substrate and the skin. The method also includes coupling at least a portion of the skin to the substrate and introducing a material (240) into the cavity after securing at least a portion of the skin to the substrate. The skin and the material introduced into the cavity form a cushioned region for the vehicle component.

Term
Term ended
Projected expiry passed 26 May 2024, 2.3 years ago.
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1 claim: 1 independent, 0 dependent
- 1Claims Zastrzeżenia patentowe 1. Sposób wytwarzania panelu wewnętrznego (210) lub panelu (710) drzwi dla pojazdu obejmujący:A method of manufacturing an inner panel (210) or a door panel (710) for a vehicle comprising: providing a relatively rigid substrate (230) and a relatively flexible skin (222), the substrate (230) having a channel (234) and the skin (222) having a projection (226) that is formed by a U-shaped skin portion (222). , the sheathing (222) is provided adjacent to at least a portion of the substrate (230), so that between the substrate (230) and the skin (222) is formedEka (216), connecting at least a portion of the skin (222) to the substrate (230) by inserting the U-shaped shell portion (222) into the channel (234) inserting the material (240) into the cavity (216) after inserting the shell portion (222) lithiumery U in the channel (234). wherein: zapewnienie stosunkowo sztywnego podłoża (230) oraz stosunkowo elastycznego poszycia (222), przy czym podłoże (230) posiada kanał (234) a poszycie (222) posiada występ (226), który jest tworzony przez część poszycia (222) w kształcie litery U, zapewnione poszycia (222) w sąsiedztwie co najmniej części podłoża (230) tak, że między podłożem (230) a poszyciem (222) jest utworzona wnęka (216), połączenie co najmniej części poszycia (222) z podłożem (230) przez wprowadzenie części poszycia (222) w kształcie litery U w kanał (234) wprowadzenie materiału (240) do wnęki (216) po wprowadzeniu części poszycia (222) w kształcie litery U w kanał (234), w którym: poszycie (222) oraz materiał (240) wprowadzany w pustą przestrzeń (216) tworzą wyściełany obszar dla komponentu (210) pojazdu, materiał (240) wprowadzany we wnękę (216) jest rozszerzającym się poiimerowym materiałem piankowym. the skin (222) and the material (240) inserted into the hollow space (216) form a padded area for the vehicle component (210), the material (240) inserted into the cavity (216) is an expanding polymeric foam material. 2. Sposób według zastrzeżenia 1, w którym komponent (210) jest wytwarzany tak, że poszycie (222) jest zapewniane w obszarze wewnętrznego panelu, z którym pasażer ma kontakt w pojeździe. A method according to claim 1, wherein the component (210) is manufactured such that the skin (222) is provided in the region of the inner panel with which the passenger is in contact with the vehicle. 3. Sposób według zastrzeżenia 1, obejmujący ponadto krok wytwarzania poszycia (222) wykorzystujący co najmniej jeden spośród procesu formowania osadowego, procesu formowania próżniowego, procesu formowania wtryskowego, procesu wyciskania, bądź procesu odlewania. The method of claim 1, further comprising a plurality of shell manufacturing step (222) using at least one of the slush molding process, the vacuum forming process, the injection molding process, the extrusion process, or the casting process. 4. Sposób według zastrzeżenia 1, w którym poszycie (222) jest wytwarzane z materiału wybranego z grupy składającej się z tekstyliów, poliuretanu, polichlorku winylu, termoplastycznej olefiny, oraz ich połączeń. The method of claim 1, wherein the skin (222) is fabricated from a material selected from the group consisting of textiles, polyurethane, polyvinyl chloride, thermoplastic olefin, and combinations thereof. 5. Sposób według zastrzeżenia 1, w którym podłoże (230) zawiera materiał (240) wybrany z grupy składającej się z metalu, stopu metalu oraz polimeru. The method of claim 1, wherein the substrate (230) comprises a material (240) selected from the group consisting of a metal, a metal alloy, and a polymer. 6. Sposób według zastrzeżenia 1, obejmujący ponadto wytwarzanie wiązania między materiałem wprowadzanym do wnęki (216), a co najmniej jednym spośród podłoża (230) oraz poszycia (222). The method of claim 1, further comprising forming a bond between the material entering the cavity (216) and at least one of the substrate (230) and plating (222). 7. Sposób według zastrzeżenia 1, w którym krok łączenia co najmniej jednej części poszycia (322) z podłożem (330) obejmuje ponadto zastosowanie urządzenia próżniowego. The method of claim 1, wherein the step of connecting at least one portion of the skin (322) to the substrate (330) further comprises using a vacuum device. 8. Sposób według zastrzeżenia 7, w którym podłoże (330) zawiera co najmniej jeden otwór (338), zaś powietrze znajdujące się wewnątrz pustej przestrzeni (316) jest zasysane poprzez otwór (338) przez urządzenie próżniowe. A method according to claim 7, wherein the substrate (330) includes at least one aperture (338) and air within the void (316) is sucked through the aperture (338) through a vacuum device. 9. Sposób według zastrzeżenia 7, w którym podłoże (330) zawiera zapewniony w nim otwór (338), zaś krok stosowania urządzenia próżniowego obejmuje zasysanie powietrza poprzez otwór (338) w podłożu (330) w celu przytwierdzenia poszycia (322) do podłoża (330). The method of claim 7, wherein the substrate (330) includes an aperture provided therein (338), and the step of using a vacuum device includes sucking air through an aperture (338) in the substrate (330) to secure the skin (322) to the substrate ( 330). 10. Sposób według zastrzeżenia 9, w którym komponent (410) zawiera powierzchnię zewnętrzną (412) posiadającą granicę (424) utworzoną między poszyciem (422) a podłożem (430), oraz w którym otwór (438) jest zapewniony w podłożu (430) w miejscu pośrednim względem miejsca granicy (424) oraz miejsca, gdzie występ (426) łączy się z kanałem (428). The method according to claim 9, wherein the component (410) comprises an outer surface (412) having a limit (424) formed between the skin (422) and the substrate (430), and wherein the opening (438) is provided in the substrate (430) in an intermediate place relative to the border location (424) and the place where the projection (426) connects to the channel (428). 11. Sposób według zastrzeżenia 9, w którym komponent (510) zawiera powierzchnię zewnętrzną posiadającą granicę utworzoną między poszyciem (522) a podłożem (530), oraz w którym miejsce, gdzie występ (526) łączy się z kanałem (534) jest zapewnione między miejscem granicy a miejscem otworu (538). The method according to claim 9, wherein the component (510) comprises an outer surface having a boundary formed between the skin (522) and the substrate (530), and wherein the place where the projection (526) connects to the channel (534) is provided between the place of the border and the place of the hole (538). 12. Interior panel (210) or door panel (710) for a vehicle, including: 12. Panel wewnętrzny (210) lub panel (710) drzwi dla pojazdu zawierający: a substrate (230) having a channel (234);podłoże (230) posiadające kanał (234);13. 13. . . 15. 15. 16. 16. 17. 17. 18. 18. a sheathing (222) having a projection (226) formed by a U-shaped skin portion (222) inserted into the channel (234);poszycie (222) posiadające występ (226), tworzony przez część poszycia (222) w kształcie litery U, wprowadzany w kanał (234);a foam material (240) disposed in an empty space (216) between the skin (222) and the substrate (230), wherein the skin (222) and the foam material form a padded area for the vehicle component. materiał piankowy (240) umieszczony w pustej przestrzeni (216) między poszyciem (222) a podłożem (230), w którym poszycie (222) oraz materiał piankowy tworzą wyściełany obszar dla komponentu pojazdu. Panel według zastrzeżenia 12, w którym podłoże (330) zawiera co najmniej jeden otwór próżniowy (338), który rozpościera się przez podłoże (330). The panel according to claim 12, wherein the substrate (330) comprises at least one vacuum port (338) that extends through the substrate (330). Panel według zastrzeżenia 13, w którym otwór próżniowy znajduje się w kanale (634). The panel according to claim 13, wherein the vacuum hole is in the duct (634). Panel według próżniowy (538) (530) znajduje poszycia (522). The panel according to vacuum (538) (530) is provided with sheathing (522). claim 13, in which the opening extends through the substrate between the protrusion (526) and the edge zastrzeżenia 13, w którym otwór rozpościerający się przez podłoże się między występem (526) a krawędzią Panel według zastrzeżenia 13, w którym występ (426) znajduje się między otworem próżniowym (438) rozpościerającym się przez podłoże (430) a krawędzią poszycia (422). The panel according to claim 13, wherein the projection (426) is located between the vacuum port (438) extending through the substrate (430) and the skin edge (422). Panel według zastrzeżenia 12, rozpościera się zasadniczo poszycia (622). The panel according to claim 12, extends substantially to the skin (622). Panel według zastrzeżenia 13, w którym występ (626) wokół całego obwodu w którym bezpośrednie połączenie występu (626) z kanałem (634) zapewnia co najmniej jedno spośród uszczelnienia nieprzepuszczalnego dla powietrza oraz dla wody. The panel according to claim 13, wherein the protrusion (626) around the entire periphery in which the direct connection of the protrusion (626) to the channel (634) provides at least one of the air-tight seal and water. 19. Panel według zastrzeżenia 12, w którym poszycie (622) zawiera kołnierz (628), który rozpościera się na zewnątrz od występu (626). The panel according to claim 12, wherein the skin (622) comprises a collar (628) that extends outwardly from the projection (626). 20. A panel according to claim 19, wherein the flange (628) contacts the surface of the substrate (630) adjacent to the duct (634). 20. Panel według zastrzeżenia 19, w którym kołnierz (628) styka się z powierzchnią podłoża (630) w sąsiedztwie do kanału (634). Johnson Controls Technology Company Pełnomocnik: Johnson Controls Technology Company. Plenipotentiary: 1/6 1/6 ΕΡ 1 684 963 Β1 ΕΡ 1 684 963 Β1 FIG. 1 FIG. 1 FIG. 2 FIG. 2 78P29458PLOO 78P29458PLOO 2/6 2/6 ER 1 684 963 Β1 ER 1 684 963 Β1 FIG.3 FIG.3 Ί Ί 216 216 FIG.5 FIG.5 78P29458PL00 78P29458PL00 3/6 3/6 ΕΡ 1 684 963 Β1 ο ΕΡ 1 684 963 Β1 ο ιη co ιη what What co C \ l C\l CO WHAT 78P29458PL00 78P29458PL00 4/6 4/6 ΕΡ 1 684 963 Β1 ΕΡ 1 684 963 Β1 FIG. 8 FIG. 8 550 550 78P29458PLOO 78P29458PLOO 5/6 5/6 78P29458PL00 78P29458PL00 6/6 6/6 ΕΡ 1 684 963 Β1 ΕΡ 1 684 963 Β1 78P29458PL00 78P29458PL00
62 paragraphs, as filed
The present invention relates to panels for use in vehicles (e.g., motor vehicles, such as cars, lorries, airplanes, boats, etc.) according to claim 12 and methods for producing such components according to claim 1. More specifically, the present invention relates to interior panels for vehicles that include at least one relatively soft (e.g., padded or padded) portion.
[0002] The upholstered or padded parts of the vehicle interior, such as panels (e.g., instrument panels, door panels, etc.) conventionally comprise a substrate made of a relatively stiff material, a relatively soft core (e.g., foam core), and an outer surface or shell. For example, the vehicle door panel may be padded to provide additional comfort to the vehicle user when the user's body part abuts or contacts the door panel. Various methods are known in the art for providing such padding, see e.g. US-A-4992224, although such known methods do not provide certain advantageous features and / or combination of features.
[0003] For example, one difficulty in manufacturing panels having padded parts is that to optimize the positioning of the padded parts so that the padded parts are only provided in areas for which the user resists (e.g., contacts) can be difficult. For example, passengers do not come into contact with certain areas of the vehicle interior trim panels, such as locations on the door panels near the floor of the vehicle. The provision of padded parts in such areas may be little or not justified at all. In addition, providing padded parts or regions in areas where it is not required increases unnecessarily the expense (e.g., material, labor, and equipment) and can also excessively increase the weight of the vehicle.
[0004] In order to provide localized padded parts for vehicle interior components, one known method involves connecting a padded component to a rigid component. For example, a relatively rigid panel (e.g., door panel) may have a component attached to it, which comprises a relatively rigid substrate, a relatively soft sheath, and a foam inner portion. One difficulty with such a method is that such a method requires the use of additional components (e.g., an additional substrate, screws or other connecting devices to fix the panel substrate to the substrate of the padded portion, etc.), which increases both the weight and the cost of the finished product.
[0005] Therefore, there is a need for a method for manufacturing components, such as panels or other structures for use in vehicles that comprise a relatively soft or padded portion or segment. There is also a need to provide components that have local padding areas that are optimized based on the location likely to be based on the vehicle user or other person. There is also a need to provide a component having local padding areas that has a reduced mass and requires less material than conventional components having padded areas. There is also a need to provide an integrally formed vehicle component that includes local padding areas. There is also a need to provide components and a method of manufacturing components that: o be manufactured in a relatively simple and efficient manner, with reduced manufacturing and material costs. There is also a need to provide a production method for producing components having one or more padded parts that uses existing equipment.
BRIEF DESCRIPTION OF THE DRAWINGS [0006] FIGURE 1 is a perspective view of a component or assembly for use in a vehicle according to an exemplary embodiment.
[0007] FIGURE 2 is a top view of the component shown in FIGURE 1.
[0008] FIGURE 3 is a top view illustrating a component for use in a vehicle according to another embodiment.
[0009] FIGURE 4 is a partial cross-sectional view of a component according to another embodiment.
[0010] FIGURE 5 is a partial cross-sectional side view of a portion of the component shown in FIGURE 4.
[0011] FIGURE 6 is a partial cross-sectional side view of a component similar to that shown in FIGURE 4, illustrating the operation of forming a component. [0012] FIGURE 7 is a partial cross-sectional side view of a portion of a component according to another embodiment.
[0013] FIGURE 8 is a partial cross-sectional side view of a component according to another embodiment illustrating a component manufacturing operation.
[0014] FIGURES 9A-9B show partial cross-sections in a side view of the skin and substrate for a component according to another embodiment.
[0015] FIGURE 10 is a partial cross-sectional side view illustrating the connection of the skin to the substrate z<sup>loam</sup>us'trowan<sup>s</sup>ch on <sup>FIGURE 9</sup>.
[0016] FIGURE 11 is a perspective view of a door panel having areas of cushioning according to an exemplary embodiment.
DETAILED DESCRIPTION OF EMBODIMENTS [0017] FIGURES 1 and 2 illustrate one embodiment of a component or assembly 10 such as a panel or other structure for use in a vehicle (e.g., motor vehicles, such as passenger cars, lorries, buses, etc .; airplanes, boats etc.). Such components can be provided in a wide variety of sizes, shapes and configurations according to various embodiments. For example, such components may be used in the interior passenger compartment of a vehicle, and may be used in the form of door panels, dashboards, instrument panels, consoles, side wall finishes, overhead liners, or other vehicle components or parts thereof. FIGURE 11 depicts one embodiment of a door panel 710.
[0018] The component 10 is provided with one or more local or discrete areas that are soft or padded in areas that the passenger or other person is in contact. For example, a door panel, such as the door panel 710 shown in FIGURE 11, may be provided with padding in areas where a part of the passenger's body is likely to contact the door (e.g., on the armrest, adjacent to the window sill, etc.) without the need to provide padding all over the door (see, e.g., FIGURE 11, in which areas in which the passenger typically does not come into contact are hard plastic surfaces 730). In this way, padding areas can be optimized based on the typical practical experience of passengers. One advantageous feature of such a method is that
[0019] Methods for providing local, soft or padded areas in the manner described herein may be used to provide components having a wide variety of configurations. For example, a door panel may be provided that includes one or more islands of hard plastic (e.g., grilles, decorative accents, seams, inner handles for closing doors, etc.). In another example, complex geometries (e.g., armrests in the shape of stops x, y, z, etc.) may be formed. In yet another example, the door panel may include elevated (e.g., raised) or recessed padding areas to enhance aesthetics.
[0020] According to an embodiment, the component 10 comprises a member or element in the form of a relatively rigid substrate, base, or layer 30 (to which reference is made here for simplicity as "substrate"). A padded or padded member or member 20 is provided in or adjacent to at least a portion of the substrate 30, and includes a cover or sheath 22 and filler material (see e.g. filler material 240 shown in FIGURE 4 with respect to component 210) provided indirectly or between the skin 22 and the substrate 30. It should be noted that, according to various embodiments, the entire substrate or part thereof may have a padded or padded part in its vicinity. For example, according to an embodiment, the skin is applied adjacent to the substrate, and the portions of the skin may be in direct contact with the substrate, while other parts of the plating can be separated from the substrate by the filling material. In this way, local areas of cushioning can be provided while maintaining the appearance and pleasant feel of the plating even in areas not lined with padding.
[0021] The substrate 30 may be made of a suitable material comprising a plurality of different metals (e.g., aluminum, magnesium, metal, etc.) or polymers (e.g., polypropylene, polyethylene, copolymers, etc.). The substrate 30 can be formed freely, from a wide selection of shapes, sizes and configurations e.g. the embodiment shown in FIGURE 3, wherein the substrate has a substantially square shape with rounded corners, and an embodiment shown in FIGURE 11, which shows a door panel having local areas padding), and may include a variety of other features not shown in FIGURES 1 and 2 (e.g., openings for door handle locks, integrally shaped structures, etc.). The substrate 30 may be a standalone component or may be a component in a larger assembly (e.g.
[0022] According to an embodiment, the padded member 20 is provided above or over at least a portion of the substrate 30. The cover 22 forms an outer surface 12 (e.g.
at least part of the part visible from the passenger compartment, which is usually related to the "A" surface, etc.
Component 10. According to an embodiment, part of the substrate 30 forms part of the surface with sheathing 22 may be in the form of a surface. The border 24 may or may be a "seamless" appearance made of a relatively material comprising or elastic polymeric (e.g.
12. A boundary 24 (e.g., a contact, a seam, or a joint) must be provided between the substrate 30.
visible on the outer surface filled with material to provide component 10.
[0023] According to an embodiment, the skin 22 is a soft material polyurethane, polyvinyl chloride (PVC), thermoplastic olefin (TPO), etc.). According to other embodiments, the skin can be made of other materials, including textiles such as fabric, leather, composite materials, layered materials (e.g., a skin layer applied to a layer of polymeric material), etc.
According to a preferred embodiment, the sheath 22 is provided on the substrate 30 in such a way that the space or emptiness (e.g., void or gap) (see e.g. space 216 shown in FIGURE 4) is formed indirectly or between at least part of plating 22 and substrate 30. According to one embodiment, substantially the entire plank 22 spaced from the border 24 between the substrate 30 and the plating 22 is spaced from the substrate 30 by space or emptiness (e.g., to form an empty space). According to another embodiment, the shell parts can be provided in direct contact with the substrate such that one or more spaces or voids are provided between the skin and the substrate in one or more specific areas. The specific design chosen may depend on many different factors,
In the hollow space between the substrate 30 and the skin 22, a material (e.g., a filler material) such as material 240 shown in FIGURE 4 is provided or filled to perform the filler function. It is envisaged that such material function as a relatively soft or cushioning material to provide a padded member 20 with at least a portion of its relatively soft or padded property. According to an embodiment, the filler material is a polymeric material, such as a foam material (e.g., urethane foam). The filling material in liquid form is introduced into the cavity and then expands to fill the cavity. For example, where the filler material is provided to the matte material after: le / vk, the foam reacts to expand and form a cellular structure within the cavity.
[0026] According to an embodiment, the skin 22 is manufactured or produced using a slush molding process. In a sludge molding process, a thermoplastic material in a liquid or powdered form is introduced into a temperature controlled mold to form a damp skin adjacent to the walls of the mold. After the plating has been formed, the excess material is removed from the mold, the cover is left to cure and cool, after which the plating is removed from the mold. One advantage of using a slush molding process is that it is relatively inexpensive and efficient in producing relatively complex plating geometries.
[0027] According to another embodiment, the skin 222 is manufactured or manufactured using a vacuum forming process. In a vacuum forming process, the pre-cut or molded sheet of polymeric material is placed in a mold and heated to soften the material. A vacuum is supplied to the mold, which attracts the softened polymeric material to the walls of the mold. The polymeric material then cools and retains the shape determined by the walls of the mold.
[0028] According to other embodiments, the skin 222 may be manufactured according to various other methods. For example, the skin 22 may be manufactured by an injection molding process, an extrusion process, a casting process (e.g., gravity casting), or any other suitable process for forming a polymer skin.
[0029] According to an embodiment in which the skin 222 is made of a polymeric material, the skin 22 has a thickness of approximately 0.5 to 3.0 millimeters, and most preferably approximately 1.0 to
1.5 millimeters.
[0030] Poszycie 22 może posiadać rozmiar, kształt, oraz konfigurację, która jest przystosowana lub skonfigurowana do elementów zawartych w podłożu. Według jednego przykładu wykonania (przedstawionego np. na FIGURZE 3), podłoże 130 może zawierać wycięcie lub zagłębienie, zaś poszycie 122 może być zapewnione wewnątrz wycięcia. Według innego przykładu wykonania (przedstawionego np. na FIGURACH 4 - 5), podłoże 230 może być zapewnione tak, że wystaje ono na zewnątrz, zaś poszycie 222 może być naniesione na podłoże 230. Rozmiar, kształt oraz konfiguracja poszycia i podłoża mogą przyjmować dowolna liczbę postaci, oraz tworzone mogą być stosunkowo złożone geometrie. Na przykład, poszycie może być zapewnione na podłożu w postaci panelu drzwi tak, że poszycie zawija się wokół krawędzi (np. tylnej krawędzi) panelu. Fachowiec w tej dziedzinie techniki dostrzeże, iż pod tym względem istnieje wiele możliwości.
[0031] As shown in FIGURE 1, boundary 24 (e.g., seam or connection) is formed or provided between sheathing 22 and substrate 30 such that substrate 30 forms a border 32 around skirt 22. The size, shape, and configuration of border 24 may vary in various embodiments. The limit 24 can also be eliminated or its size can be reduced by using a material to at least partially fill the border 24 (e.g., seal, adhesive, liquid polymer, or other materials). According to other embodiments, the skin can be provided in such a way that there is no visible boundary (e.g., the skin is provided on all parts of the substrate such that no boundary is visible on the outer surface of the component).
[0032] The cover 22 and / or the substrate 30 may comprise means configured to connect at least a portion of the skin to the substrate 30. The connection may be made by mechanical interconnection (e.g., friction or interference fit) or other
FIGURES 4 combinations of mechanisms. According to an embodiment, the skin is bonded to the substrate in a manner that provides a substantially impermeable air and / or water seal between the skin and the substrate.
[0033] FIGURES 4 and 5 illustrate one embodiment illustrating the connection between the skin 222 and the substrate 230 (FIGURE 5 is an enlarged section showing in more detail the protruding or extension 226 (shown, for example, as part of a substantially U-shaped skin) extending from the skin to the inner opening or channel 234 (e.g., groove, recesses, indentations, etc.) provided or formed in the substrate 230. The size, shape and configuration of the projection 226 and channel 234 can be provided such that projection 226 and channel 234 combine when they are folded together (e.g., the projection may comprise a substantially curved or curved beam having a radius similar to the radius for a substantially rounded or a part that provides a curved portion of the channel or opening, as illustrated in FIGURES 9-10,which represent a substrate 630 having a channel 634 provided therein and a skin 622 having a rounded extension<sup>62</sup>8; I<sup>k</sup> the cover 622 is joined by a projection 626 shown and a flange or on. FIGURE 10, substrate 630, and between them is boundary 624, protrusion 626 is gripped inside hole 634). The protrusion 226 may include a collar or extension 228 that extends therefrom to provide improved fit between the skin 222 and the substrate 230.
[0034] For any protrusion and channel, any of a plurality of different configurations may be used, of which several non-exclusive examples are illustrated in the appended
FIGURES. The protrusion may be formed on the skin plating by forming the plating portions in a mold (e.g., to provide a "curled" plating edge).
configuration to create a projection) or by forming a projection after removing the plating from the mold. The protrusion may be integral with the skin or may be manufactured separately and attached to it using an adhesive or other connector. The position of the projection and channel can be reversed so that the channel is formed at least in the shell part and one or more protrusions are formed in the substrate so that the protrusion (s) of the substrate can be inserted into the channel (s) formed in the skin to provide mechanical sealing between the skin and the ground.
One or both of the projection 226 and the walls or surfaces of the channel 234 may be relatively flexible and / or resilient so that insertion of the projection 226 into the channel 234 bends or extends one of the projection 226 and the walls or surface 234. After inserting the projection 226 in channel 234, the elastic and / or resilient component can return to its state prior to insertion to connect the skin 222 to the substrate 230. [0036] According to the embodiment, the liner 222 and the substrate 230 are combined with such that a substantially impermeable air and / or water seal is provided between the skin and the substrate. In one example, the skin 222 includes a projection that extends substantially all around the perimeter of the skin 222, and the substrate 230 includes a channel 234, which extends substantially all around the circumference of the area where the skin 222 is provided. The protrusion 226 is pressed or positioned in the channel 234 to form a seal around substantially the entire circumference of the skin 222 to form a seal. According to an exemplary embodiment, one or both of the projection 226 and channel 234 can extend only partially around its circumference to provide local sealing of the skin 222 to the substrate 230 (e.g., the skin may include a plurality of projections that are provided with gaps around the perimeter of the skin). Various sizes, shapes and configurations can be used for the projection and the channel to connect the skin to the substrate. to form a seal around substantially the entire perimeter of the skin 222 to form a seal. According to an exemplary embodiment, one or both of the projection 226 and channel 234 can extend only partially around its circumference to provide local sealing of the skin 222 to the substrate 230 (e.g., the skin may include a plurality of projections that are provided with gaps around the perimeter of the skin). Various sizes, shapes and configurations can be used for the projection and the channel to connect the skin to the substrate. to form a seal around substantially the entire perimeter of the skin 222 to form a seal. According to an exemplary embodiment, one or both of the projection 226 and channel 234 can extend only partially around its circumference to provide local sealing of the skin 222 to the substrate 230 (e.g., the skin may include a plurality of projections that are provided with gaps around the perimeter of the skin). Various sizes, shapes and configurations can be used for the projection and the channel to connect the skin to the substrate. which are provided with breaks around the plating circumference). Various sizes, shapes and configurations can be used for the projection and the channel to connect the skin to the substrate. which are provided with breaks around the plating circumference). Various sizes, shapes and configurations can be used for the projection and the channel to connect the skin to the substrate.
According to another embodiment, the skin includes one or more elements (e.g., protrusions) that are drawn into an opening such as a groove, channel or other structure provided in the substrate by means of a vacuum or other pressure or force. For example, the skin may include one or more protrusions that extend over a portion of the path around the perimeter of the skin, and the protrusions may be inserted into the opening provided in the substrate. In this embodiment, the skin is held in place by applying a vacuum that removes the air between the projections and the walls of the opening. In this way, a substantially impermeable air and / or water seal can be formed between the skin and the undercoat.
[0038] FIGURE 6 shows one embodiment of component 310, in which hole 336 is formed or provided in substrate 330; in order to fix the skin to the substrate 330, a vacuum can be sucked through one or more openings 338 formed in the channel 334 formed in the substrate 330. Vacuum box 350 may be used to suck in the vacuum, and it may be of sufficient size to allow the filling material 340 to flow into the vacuum box 350 during manufacture.
[0039] In contrast to the embodiment shown in FIGURE 6, one or more openings provided in the substrate to allow the use of a vacuum may be provided at other locations in the substrate (e.g., instead of directly adjacent or adjacent to the projection provided on the skin). For example, FIGURE 7 illustrates an embodiment of a component 410 having a skin 422 and a substrate 430 with a limit 424 provided therebetween, wherein the opening 438 is provided adjacent to or near the boundary 424 between the skin plating.
422 and substrate 430. In such an embodiment, a retainer or push button is provided
423 to provide space for the user to press the tab 426 into the channel 428. A filler material 440 is provided between the skin 422 and the substrate 430. [0040] According to another embodiment of the component 510 shown in FIGURE 8, the projection 526 of the skin 522 is provided in the channel 534 the substrate 530, and the opening 538 is formed in a substrate 530 underlying the flange 528 provided in the skin 522. That is, the opening 538 is provided such that it is on the side of the projection 526 opposite the boundary 524 formed between the skin 522 a.
530. The vacuum box 550 forms a chamber adjacent to the opening 538, and a filler material 540 is provided between and the substrate 530.
[0041] According to one embodiment, both mechanical connection means (e.g., a press-fitted projection (protrusions) and a duct (s)) and vacuum connection means can be provided. According to such an embodiment, the skin includes one or more protrusions that are fitted into one or more openings to mechanically fix the skin to the vacuum substrate 522 of the substrate 522, and the substrate also includes one or more openings to allow suction through the vacuum for anchoring plating to the ground. In any of the embodiments illustrated in FIGURES 6-8 (or in other embodiments), the projection can provide a mechanical connection in addition to the seal provided by the use of a vacuum or can only act as a guide,
[0042] FIGURE 6 illustrates an embodiment of the mechanism for introducing material into a space or void 316 formed between the skin 322 and the substrate 330. According to this embodiment, two openings 338 are provided in the substrate 330 to allow vacuum suction. In order to fix the skin 322 to the substrate 330, a vacuum is created by using vacuum boxes 350 to suck the vacuum and fix the skin 322 to the substrate 330 in the areas of the openings 338). For fixing the skin 322 to the substrate 330, a mechanical connection between the projections 326 and the channels 334 can also be used.
[0043] After attaching the skin 322 to the substrate 330 using vacuum and / or mechanical means, foam or other filler material 340 is inserted into the cavity 316 through a tube or filling nozzle 360 (e.g., by gravity injection or flooding). The fill tube 360 is connected to a slit or aperture 336 formed in a portion of the substrate 330 to allow insertion of the fill material 340 into the cavity 316. Because the skin 322 is joined to the substrate substantially impervious to water (e.g., by vacuum in a manner and / or mechanical manner). connecting mechanisms), air and / or filler material 340 does not enter the vacuum box 350 through openings 338. While the embodiment shown in FIGURE 6 illustrates a filling tube 360 that has an interior surface 362,
360 according to various others and the tube for examples of filling the workmanship.
[0044] The number, size, shape and configuration of the openings for enabling vacuum suction and for attachment to the filling tube can vary according to other embodiments. For example, more than one filling tube may be attached to the substrate at different locations, and more than one opening may be provided for attaching such filling tubes. The various features of the openings can be optimized according to various factors, including manufacturing, costs, and other factors.
[0045] In accordance with an embodiment, the backboard is attached to the substrate in a manner that does not require the use of a vacuum (e.g., mechanical tacking or connection between a part of the skin and a part of the substrate). In such an embodiment, the vacuum boxes (FIGURE 6) may be omitted, whereby the mechanical connection provides an impermeable air and / or water seal between the skin and the substrate. The mechanical connection is intended to connect the skin to the substrate in a way that does not allow the release of foam or other filler material.
[0046] According to an embodiment, the method of producing a component having one or more padded areas includes inserting or placing a substrate or parts thereof in a mold or other instrumentation, such as an in situ foaming tool having a two-mouth configuration. One prfted tool is a composite / aluminum tool manufactured by EPW, registered in Elkhsrt, Indiana. The substrate is placed in a mold such that the "A" side or part of the outer surface faces outwards (i.e., the back of the substrate does not contact the mold walls). [0047] The sheathing (e.g., a sediment-formed or vacuum-formed polymer sheath) is bonded to the substrate at one or more locations by mechanical and / or vacuum means. E.g, the cover may be joined to the substrate by inserting protrusions formed on the skin into openings such as channels or grooves formed in the substrate to mechanically connect the skin to the substrate. According to various embodiments, the vacuum may be sucked in to attach the skin to the substrate in addition to or instead of a mechanical connection (e.g., using one or more vacuum openings formed in the substrate).
[0048] After attaching the skin to the substrate, the mold or tooling is closed. The foam or other filler material is introduced into one or more cavities formed between or indirectly to the skin and substrate to provide a relatively soft and cushioned material. An opening formed in a substrate that provides an entry point to one or more voids provided between the skin and the substrate is joined by one or more filler tubs or other devices. One or more ventilation openings may also be provided in the substrate to reduce the amount of carbon dioxide or other gases accumulating inside the component during the filling operation.
[0049] The wiping component, the substrate and the foam, is then taken from the mold or tooling. The plating is connected to the ground by means of mechanical means (eg joining the projection with the opening) as well as the interaction between the filling material and the skin and the substrate. For example, a bond may be formed between the undercoat and the foam provided in the empty space. According to an alternative embodiment, adhesive may be provided on one or both of the substrate and the skin from the interior of the hollow space to bond the foam to them.
[0050] In addition to or instead of the above-described process steps, various other process steps may be used. For example, it may be necessary to seal or close one or more openings provided in the substrate after the filling operation (e.g., to prevent the foam or filler material from escaping). In another example, the mold can be rotated after inserting the plating and substrate into the mold and closing the mold before filling the cavity or voids with the filling material.
[0051] For the production of components having a wide variety of geometries and complexities, various solutions according to the present disclosure may be used. FIGURE 11 depicts one embodiment of component 710 in the form of a door panel for a vehicle. Component 710 includes a substrate 730 made of a relatively rigid material, such as a hard plastic or the like, and a plurality of members or elements that are described as locally padded or soft areas (e.g., designated reference numbers 720, 722, and 724). At different locations on component 710, a finishing material (e.g., plastic, wood, metal, etc.) may also be provided.
[0052] The members 720, 722 and 7 can be made simultaneously or in a further production method, and can be made of the same or different materials (e.g., the member 720 may have a different cover and / or a filling material than that used for the members 722). and 724, for example, the plating color of the member 720 may vary for aesthetic reasons and / or the member 720 may use other materials, since it is likely that the driver or passenger will have a lot of contact with the member 720 (e.g., the driver or passenger may support the elbow or hand against section 720)). [<sup>005</sup>3] Cons<sup>t</sup>ru<sup>k</sup>the vehicle shown and the arrangement of components of the component in various embodiments are for illustrative purposes only. Although only a few embodiments of the present invention have been described in detail in the present disclosure, those skilled in the art reviewing the present disclosure will readily recognize that many modifications are possible (e.g., changes in size, dimensions, design, shapes and proportions of different elements, parameter values, assembly systems, the use of materials, colors, orientation, etc.), without significantly going beyond the innovative solutions and advantages of the object referred to (eg the color of the plating may be different from the color of the substrate or may be essentially the same color as the substrate). E.g, the elements shown integrally formed may be constructed of a plurality of parts or elements (e.g., projections extending from the substrate to connect the plating to the substrate may be integrally formed with the plating or made separately and attached or glued to the substrate), the position of the elements may be reversed or otherwise modified (e.g., projections may be provided in the substrate to connect to an opening such as a channel or groove formed in the skin), and the nature or number of separate elements or positions may be changed or modified (e.g., number of holes provided in the substrate) for receiving the filling material may vary according to any of a number of factors). It should be noted that the elements and / or assemblies of the system can be constructed from a wide selection of materials, which provide sufficient strength or durability, including any of a wide range of formable plastics (such as high impact plastics) in any of a wide selection of colors, textures and joints. Components such as those shown here can also be used for non-drive applications, including, but not limited to, furniture such as chairs, desks, benches and other furniture items. In the construction, operating conditions and arrangement of the preferred and other embodiments, other substitutions, modifications, variations and omissions may be made without departing from the scope of the present invention. including any of a wide range of formable plastics (such as high impact plastics) in any of a wide selection of colors, textures and joints. Components such as those shown here can also be used for non-drive applications, including, but not limited to, furniture such as chairs, desks, benches and other furniture items. In the construction, operating conditions and arrangement of the preferred and other embodiments, other substitutions, modifications, variations and omissions may be made without departing from the scope of the present invention. including any of a wide range of formable plastics (such as high impact plastics) in any of a wide selection of colors, textures and joints. Components such as those shown here can also be used for non-drive applications, including, but not limited to, furniture such as chairs, desks, benches and other furniture items. In the construction, operating conditions and arrangement of the preferred and other embodiments, other substitutions, modifications, variations and omissions may be made without departing from the scope of the present invention. such as chairs, desks, benches and other furniture items. In the construction, operating conditions and arrangement of the preferred and other embodiments, other substitutions, modifications, variations and omissions may be made without departing from the scope of the present invention. such as chairs, desks, benches and other furniture items. In the construction, operating conditions and arrangement of the preferred and other embodiments, other substitutions, modifications, variations and omissions may be made without departing from the scope of the present invention.
Johnson Controls Technology Company. Plenipotentiary:
78)
6 sheets
Sheet 1 Sheet 2 Sheet 3 Sheet 4 Sheet 5 Sheet 6
8 priority claims, no other members on record
Priority claims8
| Document | Office | Kind | Date |
|---|---|---|---|
| 51198803 | United States of America | P | |
| 51198803 | United States of America | P | |
| 04753313 | European Patent Office (EPO) | A | |
| 2004016467 | United States of America | W | |
| 2004016467 | United States of America | W | |
| EP20040753313 | – | – | – |
| US20030511988P | – | – | – |
| WO2004US16467 | – | – | – |
Numbers
- Publication, DOCDB
- 1684963
- Publication, EPODOC
- PL1684963T
- Application
- 753313
- Application, DOCDB
- 04753313
- Application, EPODOC
- PL20040753313T
Titles2
- English
- VEHICLE COMPONENT AND METHOD FOR MAKING A VEHICLE COMPONENT
- Polish
- Komponent pojazdu oraz sposób wytwarzania komponentu pojazdu
Classification
- CPC, 8
- B60R13/0243
- B29C44/1257
- B60R13/02
- B60R21/0428
- B60R2013/0281
- B60R2013/0287
- B60R2013/0293
- B29C44/14
- IPC, 2
- B29C44 12
- B60R13 02