Method for manufacturing an automotive interior trim component and the resultant construction thereof
AssigneeTextron Automotive Company Inc.
InventorDavid R. McCooey
Life of this patent
Estimating the term…
Abstract
An automotive interior trim panel has an outer flexible skin that overlies a rigid backing panel formed with a foam entry hole through which foam precursors are poured into a space between the skin and panel and they react and expand to generate a foam layer within the space. Tab projections are carried by the panel and extend into the foam space to at least partially cover the opening and provide rigid backing support for foam expanding in the region of the entry hole to control the density of the foam in this entry hole region such that it conforms more closely with the density of the immediate surrounding foam.
Claims13
In a method of manufacturing an automotive interior trim component having an outer pliable skin bonded to a foam layer and a rigid backing panel insert, where the skin and panel are supported in a cavity of a foam mold tool to provide a foam space between the skin and panel and foam precursors are poured into the space through a foam entry hole of the panel whereupon the precursors expand to fill the space and cure to generate the foam layer therein, the improvement comprising:
- providing a partial opening to the foam space by supporting a supplemental foam-backing structure on the panel in a position extending at least partially across the foam entry hole;
- configuring the structure to provide a supportive backing surface for the expanding foam precursors between the entry hole and the panel to control the density of the resultant foam in the foam entry hole region;
- and
- directing foam precursors into the foam space through the partial opening.
In a method of manufacturing an automotive interior trim component having an outer pliable skin bonded to a foam layer and a rigid backing panel insert, where the skin and panel are supported in a cavity of a foam mold tool to provide a foam space between the skin and panel and foam precursors are poured into the space through a foam entry hole of the panel whereupon the precursors expand to fill the space and cure to generate the foam layer therein, the improvement comprising:
- providing a supplemental foam-backing structure supported on the panel and extending at least partially across the foam entry hole to provide a supportive backing surface for the expanding foam precursors in a foam entry hole region between the entry hole and the panel to control the density of the resultant foam in the entry hole region,
- wherein the panel is formed from sheet metal and the foam-backing structure is formed as a unitary portion of the panel, and wherein the backing structure is formed by cutting at least one arcuate slot into the panel to isolate an attached tab portion, and deforming the tab portion outwardly of the panel at an angle to define the supplemental backing structure, thereby leaving behind an opening in the panel that defines the foam entry hole and that is at least partially shielded by the tab portion.
Dependencies are inferred from the claim text.