WO2008011068A2

WO2008011068A2 - Method of embossing a moulded article, method of making an embossed vehicle trim panel and mould

Info

Publication number: WO2008011068A2
Application number: PCT/US2007/016303
Authority: WO
Inventors: Nels R. Smith; Ronald A. Bozio; Scott A. Hansen
Original assignee: Johnson Controls Technology Co
Current assignee: Johnson Controls Technology Co
Priority date: 2006-07-20
Filing date: 2007-07-19
Publication date: 2008-01-24
Anticipated expiration: 2009-01-20
Also published as: WO2008011068A3

Abstract

A method of making a molded article includes providing a mold tool having at least one mold surface, removably coupling a mold insert having an embossed detail to the at least one mold surface, placing a flexible cover material into the mold tool, and applying a pressure to the cover material to form the cover material against the mold surface and the mold insert, thereby forming an impression of the embossed detail in the cover material.

Description

MOLDED ARTICLE AND METHOD OF EMBOSSING A

MOLDED ARTICLE

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 60/832,030, filed 7/20/2006, which is incorporated herein by reference in its entirety.

BACKGROUND

[0002] The following background is provided simply as an aid in understanding the disclosed subject matter and is not admitted to describe or constitute prior art. [0003] The present application relates generally to the field of molded articles or components having a substrate and having a cover material (e.g., a coverstock, etc.) with an embossed detail. In addition, the present application relates to a method of embossing a cover material (e.g., providing the cover material with a raised/depressed portion, such as a decorative element) during the preforming of the cover material or the molding of a substrate.

[0004] It is known to provide an embossed detail (e.g., a decorative element or detail, etc.) on a vehicle trim panel by permanently machining or engraving projections or recesses in a molding tool, such as a cavity or core, and then arranging a cover material over a projection, for example, and molding a substrate against the cover material so that a recess is formed in the molded article with the shape of the projection. However, such known methods require a dedicated mold tool and do not allow for changes, additions, or the like without extensive work done on the mold. It is also known to emboss a vehicle trim panel by a post molding operation. However, such post molding operations often require expensive equipment that use considerable heat, which can damage the visible surface of the trim panel. [0005] Accordingly, it would be desirable to reduce or eliminate capitol and labor- intensive processes such as machining and/or welding of an embossed detail template to a mold.

[0006] It would also be desirable to reduce or eliminate capitol and labor-intensive processes when an embossed detail needs to be modified, another embossed detail is to be added, or the like, such as for different trim levels, different vehicle models, vehicle redesigns, changes to the ornamental appearance of the embossed detail, or the like.

[0007] It would also be desirable to provide a process where an embossed detail is interchangeable or easily adaptable or modified.

[0008] To provide an inexpensive, reliable, and widely adaptable in-molded embossed detail that avoids the above-referenced and other problems would represent a significant advance in the art.

[0009] Accordingly, it would be desirable to provide a method of embossing a vehicle interior component, such as a trim panel, overhead liner or system, instrument panel, visor, seat, or the like, that includes any one or more of these or other advantageous features.

SUMMARY

[0010] One embodiment relates to a method of making a molded article, comprising providing a mold tool having at least one mold surface, removably coupling a mold insert having an embossed detail to the at least one mold surface, placing a flexible cover material into the mold tool, and applying a pressure to the cover material to form the cover material against the mold surface and the mold insert, thereby forming an impression of the embossed detail in the cover material.

[0011] Another embodiment relates to a method of making a vehicle trim panel, comprising providing a cover material, providing a mold tool having a removable insert with a contoured surface, placing the cover material into the mold tool, introducing a substrate material into the mold tool to form a substrate at least partially behind the cover material, deforming the cover material to conform to the contoured surface and form an embossed detail in the cover material, and removing the cover material and the substrate from the mold tool.

[0012] Another embodiment relates to a method of making a molded component, comprising providing a mold having a first mold surface and a second mold surface, releasably coupling an insert to one of the first mold surface and the second mold surface, placing a cover material into the mold, deforming the cover material around the insert to form an impression of the insert in the cover material, and removing the cover material with the impression from the mold.

[0013] Another embodiment relates to a mold tool comprising a first mold surface, a second mold surface, and a mold insert configured to be removably coupled to at least one of the first mold surface and the second mold surface. [0014] Various other exemplary embodiments relate to various features and combinations of features shown and described in the disclosed embodiments. Other ways in which the objects and features of the disclosed embodiments are accomplished will be described in the following specification or will become apparent to those skilled in the art after they have read this specification. Such other ways are deemed to fall within the scope of the disclosed embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] FIG. 1 is a perspective view of a vehicle according to an exemplary embodiment.

[0016] FIG. 2 is a perspective view of a portion of the interior of the vehicle shown in FIG. 1 including a trim panel according to an exemplary embodiment.

[0017] FIG. 3 is cross-section view of the trim panel of FIG. 2 taken along line 3-3 according to an exemplary embodiment.

[0018] FIG. 4 is a cross-section view of the trim panel of FIG. 2 taken along line 4-4 according to an exemplary embodiment.

[0019] FIG. 5 is a cross-section view of a mold in an open position according to an exemplary embodiment.

[0020] FIG. 6 is a cross-section view of the mold of FIG. 5 in a molding position according to an exemplary embodiment. [0021] FIG. 7 is an exploded perspective view of a trim panel and an associated mold insert according to an exemplary embodiment.

DETAILED DESCRIPTION

[0022] Referring to FIG. 1 , a vehicle 11 is shown according to an exemplary embodiment. While vehicle 11 is shown as an automobile, it should be understood that according to various alternative embodiments, vehicle 11 could be any of a wide variety of vehicles, including sport utility vehicles, buses, recreational vehicles, airplanes, etc., and the teachings herein extend to all such applications. [0023] Referring to FIG. 2, an interior 10 of vehicle 11 is shown according to an exemplary embodiment. Interior 10 is shown to include a door 12 and an instrument panel 14. Door 12 and instrument panel 14 each may comprise an outer trim component or panel 16 that is formed by a cover material 18 (e.g., a flexible member, skin, sheet, foil, coverstock, etc, all of which will be referred to as cover material 18) coupled to a substrate 20 (e.g., rigid member, base, panel, etc., all of which will be referred to as a substrate 20) for structural support. A compressible material (e.g., foam) may be provided between cover material 18 and substrate 20 (e.g., bonded to cover material 18 before cover material 18 is coupled to substrate 20). [0024] According to one embodiment, trim panel 16 also includes an embossed detail 22 (e.g., decorative detail, projection, indentation, sculptured and dimensional qualities, etc., all of which will be referred to as embossed detail 22) that is formed during the process of forming cover material 18 and/or molding substrate 20 against cover material 18. As shown in FIGS. 3 and 4, embossed detail 22 may include a variety of contours, recesses, etc. For the purposes of this disclosure, trim panel 16 coupled to door 12 will be further described, but it would be understood by a person having ordinary skill in the art reading this disclosure that trim panel 16 could be coupled to instrument panel 14, a visor, headliner, seat, console, or other surfaces within the vehicle, or used in other applications where a panel with one or more embossed details is desired.

[0025] According to one embodiment, substrate 20 provides the substantial, if not the entire, structural support for trim panel 16 generally, and may provide structural support to various components that are attached to trim panel 16 (e.g., armrests, speakers, handles, etc.). Substrate 20 may further provide an ornamental or decorative appearance. The surfaces of trim panel 16 that are visible (e.g., to an occupant) when trim panel 16 is mounted in vehicle interior 10 are generally referred to as the "A" surface or side. Portions or surfaces of substrate 20 may provide the "A" surface. Other portions or surfaces of substrate 20 may be obscured or covered by cover material 18 or other components. According to an exemplary embodiment, substrate 20 is a rigid structure and is formed by injection molding a polymer resin in a process that uses heat and pressure to inject a molten resin into a cavity formed in a mold tool.

[0026] Cover material 18 may provide an ornamental or decorative appearance to trim panel 16 using different materials, textures, colors, treatments, secondary operations (e.g., sewing), or the like. Cover material 18 may also provide a functional feature to trim panel 16, such as a soft or cushioned portion or region of trim panel 16 (e.g., a softer portion of trim panel 16 relative to substrate 20), a raised portion of trim panel 16, a different surface compared to substrate 20, or the like. According to exemplary embodiments, a substantial portion of one side of cover material 18 serves as part of the "A" surface of trim panel 16. According to one embodiment, substrate 20 is formed with a groove 24 (e.g., ditch, indentation, notch, etc.) to accept a portion or edge of cover material 18 (see, e.g., FIG. 7).

[0027] According to an exemplary embodiment, cover material 18 comprises a plurality of layers to form a laminate. According to another exemplary embodiment, cover material 18 comprises a foam layer between two polymer layers. Alternatively, cover material 18 may be formed by a single layer. Cover material 18 may be a single, unitarily formed, integral sheet, or a plurality of sections (e.g., layers, patches, etc.) coupled together (e.g., sewn, fastened, bonded, etc.).

[0028] Cover material 18 may be provided as a sheet of material (e.g., in flat sheets or rolls, etc.). According to an exemplary embodiment shown in FIG. 5, cover material 18 is a flat sheet of material. According to alternative embodiments, cover material 18 is formed into a designed shape (i.e., a "preform") using a combination of heat and/or pressure/vacuum on a sheet of material (e.g., thermoforming, vacuum forming, etc.).

[0029] As shown in FIG. 2, cover material 18 provides a portion of the A-surface of trim component 16 (e.g., resulting from a process such as insert molding, partial- mold-behind, etc.). Alternatively, cover material 18 may provide the entire A-surface of trim panel 16 (e.g., resulting from a process such as full-mold-behind, etc.), or any of a variety of arrangements or configurations.

[0030] Embossed detail 22 is provided in cover material 18 and substrate 20 and generally refers to a projecting or an indented shape, word, or other indicia (e.g., a contoured surface having raised and/or depressed portions, etc.) that provides a decorative, ornamental, and/or functional effect to a molded article such as trim panel 16. Embossed detail 22, for example, may provide any of a variety of ornamental appearances such as textures, patterns, images, indicia, text, designs, or combinations thereof that are formed on the side or surface of trim panel 16 that ultimately at least partially faces the vehicle interior 10 (e.g., the visible or "A-surface"). Alternatively, embossed detail 22 may be provided for any of a variety of purposes (e.g., instructions, notice, indicator, etc.).

[0031] Referring to FIGS. 5-7, embossed detail 22 is formed by a mold insert 26 (e.g., badge, tool insert, article, member, template stamp, etc.) removably coupled to a mold section (e.g., cavity 30 shown in FIG. 5) of a mold tool such as mold 28. Mold insert 26 may be any of a variety of structures or members that provides a "negative" of the detail (e.g., contoured surface, etc.) desired to be embossed on trim panel 16. Mold insert 26 may be removably coupled to mold 28 by an adhesive 27. According to an exemplary embodiment, adhesive 27 may be a temporary adhesive that allows for efficient removal (or replacement) of mold insert 26 and/or adhesive 27 from mold 28. Alternatively, insert 26 is coupled to the mold with tape or any of a variety of temporary attachment techniques. As such, mold 28 may be used for trim panels 16 that are formed with embossed detail 22 and for panels that are formed without embossed detail 22 (e.g., small parts runs, special editions, "custom" orders, etc.) without requiring separate mold tools. The same mold may also be used to produce a variety of panels with different details (e.g., different trim levels of a particular vehicle model).

[0032] FIGS. 5 and 6 illustrate a process for making trim panel 16 by joining cover material 18 to substrate 20 and providing embossed detail 22 according to an exemplary embodiment. FIG. 5 shows mold 28 having a first mold section (shown as cavity 30) and a second mold section (shown as core 32). Mold insert 26 is removably/temporarily coupled to cavity 30 by adhesive 27. Cover material 18 is positioned in cavity 30 between cavity 30 and core 32 when mold 28 is open. According to an exemplary embodiment, cover material 18 is mounted on projections 34, 36 (e.g., pins, etc.) extending from cavity 30 that may engage recesses such as recess 38 in core 32. According to one embodiment, projections 36 are provided on cavity 30 to push and retain the edge of cover material 18 into recesses 38 on core 32. Alternatively, cover material 18 may be press fit onto projections extending from cavity 30, placed in mold 28 by any of a variety of techniques including robotic placement, manual placement, vacuum device, adhesive, or the like, and/or may be held in place by its shape registering with the shape of the mold, or by pins or the like. [0033] Mold 28 closes (or partially closes) around cover material 18 (e.g., by moving the mold sections toward each other or one of the sections toward the other section) into a molding position so that a cavity or gap is provided between core 32 and cavity 30.

{0034] Referring to FIG. 5, molten polymer resin is injected into the space (gap, cavity, etc.) between core 32 and cover material 18 and/or cavity 30 to form substrate 20. As molten plastic resin fills the space, cover material 18 is pressed against mold insert 26 and against the surface of cavity 30. Cover material 18 is pressed (e.g., conforms) around mold insert 26 by the pressure and/or heat of the plastic resin to emboss the contours/shape of mold insert 26 into cover material 18 (and substrate 20). The presence of mold insert 26 in mold 28 during the injection of the plastic resin causes substrate 20 to form around mold insert 26.

[0035] After the plastic resin has sufficiently solidified, trim panel 16 may be removed from mold 28 upon release of the injection pressure, and, upon removal from mold 28, cover material 18 may expand (if trim panel 16 also includes a compressible material) and return to, or near to, its pre-molding thickness.

[0036] After the plastic resin forms substrate 20, trim panel 16 can undergo any of a variety of finishing operations (e.g., removing any portions of cover material 18 not attached to substrate 20 (e.g., a portion or strip containing apertures), wrapping around and coupling to a B-surface of substrate 20 (e.g., by fasteners, adhesives, welding, heat staking, or the like), etc.).

[0037J To alter or remove embossed detail 22 provided on trim panel 16, insert 26 is removed from mold 28. A new or different embossed detail may be provided by coupling a new or different mold insert to mold 28. According to an alternative embodiment, mold insert 26 may be removed, and a component may be molded without a mold insert.

(0038] According to another exemplary embodiment, embossed detail 22 may be formed during a preforming process for cover material 18. For example, referring to FIG. 5, cover material 18 may be placed proximate to (over, adjacent, etc.) cavity 30 and preformed into a desired shape (e.g., a preform shape) to include embossed detail 22. According to one embodiment, prior to or rather than injecting a substrate material (e.g., polymer resin) into mold tool 28, heat and/or a vacuum may be applied to mold tool 28 and cover material 18 such that cover material 18 is drawn by the vacuum pressure toward cavity 30 and insert 26, thereby providing a preformed shape for cover material 18 that includes embossed detail 22. According to one embodiment, cover material 18 may be preformed to include embossed detail 26 using a separate forming tool from mold tool 28. Cover material 18 may then undergo additional processing, such as injection molding processes (e.g., to form substrate 20), etc. to form trim panel 16.

[0039] It should be understood that the particular materials used to construct the exemplary embodiments are illustrative. For example, according to one exemplary embodiment, injection molded polypropylene is the method and material for making the substrate 20, but other materials may be used, including other thermoplastic resins such as polyethylene, acrylonitrile butadiene styrene ("ABS"), polyurethane nylon, any of a variety of homopolymer plastics, copolymer plastics, plastics with special additives, filled plastics, etc. Also, other molding operations may be used to form these components, such as injection compression molding, etc. according to various alternative embodiments.

[0040] According to an exemplary embodiment, cover material 18 is preferably made from a laminate of a vinyl layer, a polypropylene foam layer, and a polypropylene layer, but may be made from any of a variety of materials and compositions including fabric, cloth, carpet, natural material (e.g., leather, etc.), textile (woven, non-woven, knit, etc.), polymer (e.g., thermoplastic elastomer polyolefin (TPO), or materials formed by reaction injection molding (RIM), etc.), elastomer, or the like, or combinations thereof, and may have multiple layers (e.g., outer, inner, scrim, etc.).

[0041] Adhesive 27 may be a pressure sensitive adhesive, or alternatively, may be a film adhesive. Alternatively, adhesive 27 may be any of a variety of web, spray, or liquid adhesives.

[0042] According to an exemplary embodiment, mold insert 26 is made of aluminum formed by computer-numerical-controlled (CNC) machining operation. Alternatively, mold insert 26 may be manufactured and/or machined by any of a variety of processes, formed by rapid prototype processes (e.g., stereolithography, etc.), carved, cast, or otherwise fabricated. Mold insert 26 may alternatively be made of any of a variety of suitable material such as polymers, epoxy, metal, wood, or the like. According to another exemplary embodiment, mold insert 26 may be made from a steel material and be removably coupled to mold 28 using, for example, one or more magnets provided on or within portions of mold tool 28. [0043] It is to be understood that the invention is not limited to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments or being practiced or carried out in various ways. The molded article described in this disclosure may be employed in a variety of applications, and is generally applicable with any application where it would be beneficial to provide an embossed element to a molded article. When the molded article is a trim panel for use in a vehicle, it is suitable for use in an interior passenger compartment of a vehicle, and may find utility in the form of door panels, dashboards, instrument panels, consoles, sidewall trim, overhead liners, or other vehicle components or portions thereof. While the disclosed embodiments may be described as a vehicle trim panel, such as a door panel, the features of the disclosed embodiments are equally applicable with other applications such as other panels, molded articles and components and other office, home, educational, industrial, commercial, or consumer products which employ localized areas or regions of various or different ornamental appearances. It is also to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting. For example, the terms "substrate," "cover material," and "embossed detail" are intended to be broad terms and not terms of limitation. These components may be used with any of a variety of products or arrangements and are not intended to be limited to use with automotive applications.

[0044] It is also important to note that the construction and arrangement of the elements of the method of embossing a molded article as shown in the exemplary embodiments are illustrative only. Although only a few embodiments of the present inventions have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements show as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or other elements may be varied, and the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures and combinations. Accordingly, all such modifications are intended to be included within the scope of the present inventions. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the exemplary embodiments without departing from the scope of the present inventions.

Claims

WHAT IS CLAIMED IS:

1. A method of making a molded article comprising: providing a mold tool having at least one mold surface; removably coupling a mold insert having an embossed detail to the at least one mold surface; placing a flexible cover material into the mold tool; and applying a pressure to the cover material to form the cover material against the mold surface and the mold insert, thereby forming an impression of the embossed detail in the cover material.

2. The method of Claim 1 wherein applying the pressure to the cover material comprises applying a vacuum to the cover material and the mold tool.

3. The method of Claim 1 wherein the at least one mold surface comprises a first mold surface that generally opposes a second mold surface.

4. The method of Claim 3 further comprising: introducing a substrate material into the mold tool to form a substrate.

5. The method of Claim 4 wherein introducing the substrate material comprises injection molding the substrate material.

6. The method of Claim 1 wherein removably coupling the mold insert to the at least one mold surface comprises applying an adhesive to one of the mold insert and the at least one mold surface.

7. The method of Claim 6 wherein the adhesive is a pressure sensitive adhesive.

8. The method of Claim 1 wherein the mold insert comprises aluminum.

9. The method of Claim 1 wherein the substrate material is polypropylene.

10. A method of making a vehicle trim panel comprising: providing a cover material; providing a mold tool having a removable insert with a contoured surface; placing the cover material into the mold tool; introducing a substrate material into the mold tool to form a substrate at least partially behind the cover material; deforming the cover material to conform to the contoured surface and form an embossed detail in the cover material; and removing the cover material and the substrate from the mold tool.

11. The method of Claim 10 further comprising: removing the insert from the mold tool; and removably coupling a second insert to a surface of the mold tool.,

12. The method of Claim 10 wherein the insert comprises aluminum.

13. The method of Claim 10 further comprising removably coupling the insert to the mold tool using an adhesive.

14. The method of Claim 13 wherein the adhesive is a pressure sensitive adhesive.

15. The method of Claim 10 wherein the substrate material comprises polypropylene.

16. A method of making a molded component comprising: providing a mold having a first mold surface and a second mold surface; releasably coupling an insert to one of the first mold surface and the second mold surface; placing a cover material into the mold; deforming the cover material around the insert to form an impression of the insert in the cover material; and removing the cover material with the impression from the mold.

17. The method of Claim 16 further comprising: introducing a substrate material into the mold to form a substrate.

18. The method of Claim 16 wherein removably coupling the insert to one of the first mold surface and the second mold surface comprises providing a pressure- sensitive adhesive on at least one of the first mold surface, the second mold surface, and the pressure sensitive adhesive.

19. The method of Claim 16 wherein the insert comprises aluminum.

20. The method of Claim 16 further comprising: removing the insert from the mold.

21. A mold tool comprising: a first mold surface; a second mold surface; and a mold insert configured to be removably coupled to at least one of the first mold surface and the second mold surface.

22. The mold tool of Claim 21 wherein the mold insert is configured to be removably coupled to at least one of the first mold surface and the second mold surface using an adhesive.

23. The mold tool of Claim 21 wherein the adhesive is a pressure-sensitive adhesive.