WO1995013938A1 - Blow molded structural interior automotive parts - Google Patents
Blow molded structural interior automotive parts Download PDFInfo
- Publication number
- WO1995013938A1 WO1995013938A1 PCT/US1993/011288 US9311288W WO9513938A1 WO 1995013938 A1 WO1995013938 A1 WO 1995013938A1 US 9311288 W US9311288 W US 9311288W WO 9513938 A1 WO9513938 A1 WO 9513938A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- shell
- molding
- further characterized
- interior
- safety
- Prior art date
Links
- 239000006260 foam Substances 0.000 claims abstract description 32
- 239000004744 fabric Substances 0.000 claims abstract description 23
- 238000000465 moulding Methods 0.000 claims abstract description 22
- 239000000463 material Substances 0.000 claims abstract description 19
- 238000005192 partition Methods 0.000 claims abstract description 14
- 239000004033 plastic Substances 0.000 claims description 21
- 229920003023 plastic Polymers 0.000 claims description 21
- 238000000071 blow moulding Methods 0.000 claims description 12
- 238000000034 method Methods 0.000 claims description 12
- 239000011347 resin Substances 0.000 claims description 10
- 229920005989 resin Polymers 0.000 claims description 10
- 239000002537 cosmetic Substances 0.000 claims description 6
- 239000002984 plastic foam Substances 0.000 claims description 5
- 210000003127 knee Anatomy 0.000 claims description 4
- 235000021189 garnishes Nutrition 0.000 claims description 3
- 238000004519 manufacturing process Methods 0.000 claims description 3
- 239000004743 Polypropylene Substances 0.000 abstract description 4
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 abstract description 4
- 229920002554 vinyl polymer Polymers 0.000 abstract description 4
- -1 polypropylene Polymers 0.000 abstract 1
- 229920001155 polypropylene Polymers 0.000 abstract 1
- 208000027418 Wounds and injury Diseases 0.000 description 6
- 230000006378 damage Effects 0.000 description 6
- 208000014674 injury Diseases 0.000 description 6
- 239000004753 textile Substances 0.000 description 3
- 208000034693 Laceration Diseases 0.000 description 2
- 229910000746 Structural steel Inorganic materials 0.000 description 2
- 239000003365 glass fiber Substances 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- 230000007246 mechanism Effects 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 239000004814 polyurethane Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 230000003319 supportive effect Effects 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 230000033228 biological regulation Effects 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000002845 discoloration Methods 0.000 description 1
- 230000003203 everyday effect Effects 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 230000003116 impacting effect Effects 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 210000002414 leg Anatomy 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000002991 molded plastic Substances 0.000 description 1
- 239000003973 paint Substances 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000004616 structural foam Substances 0.000 description 1
- 239000013589 supplement Substances 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
- B62D29/04—Superstructures, understructures, or sub-units thereof, characterised by the material thereof predominantly of synthetic material
- B62D29/043—Superstructures
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
- B29C44/18—Filling preformed cavities
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
- B29C49/04—Extrusion blow-moulding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/20—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
- B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
- B60N2/68—Seat frames
- B60N2/686—Panel like structures
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
- B60R13/0237—Side or rear panels
- B60R13/025—Pillars; Roof rails
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R21/00—Arrangements or fittings on vehicles for protecting or preventing injuries to occupants or pedestrians in case of accidents or other traffic risks
- B60R21/02—Occupant safety arrangements or fittings, e.g. crash pads
- B60R21/04—Padded linings for the vehicle interior ; Energy absorbing structures associated with padded or non-padded linings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/20—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements
- B29C2049/2008—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements inside the article
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/20—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements
- B29C2049/2017—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements outside the article
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/42—Component parts, details or accessories; Auxiliary operations
- B29C49/48—Moulds
- B29C49/4802—Moulds with means for locally compressing part(s) of the parison in the main blowing cavity
- B29C2049/4805—Moulds with means for locally compressing part(s) of the parison in the main blowing cavity by closing the mould halves
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
- B29C44/14—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being a lining
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3005—Body finishings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R21/00—Arrangements or fittings on vehicles for protecting or preventing injuries to occupants or pedestrians in case of accidents or other traffic risks
- B60R21/02—Occupant safety arrangements or fittings, e.g. crash pads
- B60R21/04—Padded linings for the vehicle interior ; Energy absorbing structures associated with padded or non-padded linings
- B60R2021/0435—Padded linings for the vehicle interior ; Energy absorbing structures associated with padded or non-padded linings associated with the side or roof pillars
Definitions
- the field of this invention relates to an impact energy absorbing safety automotive trim parts for an automotive interior and a method of manufacture of the safety automotive trim parts.
- Automotive safety has been a major concern in the automotive industry for a number of years. Many safety features have been developed to reduce the jarring impact on passengers by making impact absorbing exterior parts such as energy absorbing bumpers, crush- able impact zones where the sheet metal bends and absorbs energy, and collapsible steering columns that prevent the steering column from further intrusion into the passenger compartment upon impact. Devices such as seat belts have been developed to limit the motion of occupants within the vehicle. Energy absorbing air bags have been developed to be employed upon impact to prevent the occupants from hitting the windshield and to supplement the seat belts to restrain the motion of the occupants in the forward direction.
- Padded instru ⁇ ment panels have been developed for this purpose. These instrument panels have been developed to be formed by injection molding such that a cosmetic visible skin is backed by a light foam core.
- Other plastic interior trim parts have been commonly used in the automotive industry. New materials and improved molding techniques have made it possible and economically desirable that the interior trim for A- pillars, B-pillars, floor trim pieces and inside door panels are made from plastics. Often these plastics are covered via adhesives with a cloth fabric, carpeting, or embellished with an applique or an embossment. The use of plastic interior trim parts results in an attractive passenger compartment.
- plastics Besides the economic advantage of plastics over other metal interior trim parts, the use of plastics provides sound insulation qualities and weight savings that provide a quieter ride and better fuel economy respectively.
- the material used in making automotive trim components must be strong enough to retain its shape. Often pull handles and arm rests are integrally formed within door panels so that the material must be strong enough to resist pushing and pulling forces normally encountered during normal use of the vehicle. Many of the parts are relatively large such that the plastic needs to be reinforced to make it stiff enough to span the required distance while maintaining its structural integrity.
- One common way to stiffen the plastic material is to reinforce it with glass fibers. However the glass fibers also make the component brittle and prone to shatter upon sufficient force exerted on it, the kind of force encountered during a collision. For safety purposes, a pliable flexible blow molded plastic is desirable.
- the space constraints pose a prob ⁇ lem.
- Previous struc ⁇ tural interior trim components can be padded at an occupant facing surface thereof and or layered with carpeting.
- the layers of structural components, padding and carpeting take up valuable room away from the passenger compartment.
- the vehicle must be made larger to obtain the desired sized passenger interior compartment or the passenger compartment is smaller than desired.
- a safety molding for an interior trim piece of an automotive vehicle includes a blow molded shell of resilient plastic material shaped to have an exterior facing section thereof abuttable against a surface of an exterior body of said automotive vehicle that faces the passenger compartment within the automotive vehicle.
- the blow molded shell has a first interior section that is filled with an engineered plastic foam that is normally self supportive under forces encountered during normal use of the vehicle but is energy absorbing under a compressive force over a predetermined amount that can be encountered during impact collision.
- the blow molded shell may have partitions which allow some interior sections to be foam filled and others not foam filled.
- the shell has a second interior section separated from said first interior section by a partition formed in said shell.
- the second interior section is hollow and free from said rigid foam that fills the first interior section.
- the second interior section is in a position not encountered by impact with the occupant.
- the partition is formed by a recessed groove within a shell wall that is abuttable against the surface of the exterior body of the automo- tive vehicle.
- An opposing wall of the shell is abutt ⁇ able against the wall forming the groove. The opposing wall conceals the groove from a viewpoint from within the passenger compartment.
- the safety molding has its opposing wall i.e. the wall facing the interior passenger com ⁇ partment integrally molded with a cosmetic layer of fabric, vinyl, or other cosmetic material.
- the safety trim piece can be formed in a variety of pieces and applied throughout the interior of the automotive passenger compartment.
- the shell is formed in the shape of an A-pillar and vertically disposed at the side of a front wind ⁇ shield of said automotive vehicle.
- the shell is formed in the shape of an B-pillar and vertically disposed at the rear edge of the opening in the automotive vehicle for the front door.
- the shell is formed in the shape of a rear quarter sail panel and vertically disposed at the side of the rear seats and interposed between the rear window and side window of the automotive vehicle.
- the shell is formed in the shape of a knee brace and positioned under an air bag container within the instrument panel.
- the shell can also be formed in the shape of an door panel and vertically disposed at the side of an interior facing surface of an automotive door component.
- the shell can formed in the shape of an garnish molding for the header of a windshield and horizontally disposed along a top edge of a front windshield.
- Other interior structural trim parts can also be made in accordance with the teachings of this disclosure including but not limited to head liners, top portions of seat backs, C- pillars and cargo panels.
- a method for making the safety structural interior trim piece of an automotive vehicle includes the steps of blow molding a resin parison within a cavity of a mold into a shell of resilient plastic material having the form of the structural interior trim piece and having a hollow first core therein; removing the shell from the mold; filling the hollow first core within the shell with a structural plastic foam; and curing the foam such that it is resistant to compressive and shear forces under a predetermined amount in order to provide struc ⁇ tural strength to said structural trim piece and provide compressibility of said shell and foam when a compres- sive force above said predetermined amount is exerted on said structural trim piece.
- the method also includes the mold being shaped to form a blow molded shell having a first and second core separated by a partition formed in a wall of said shell and in contact with an opposing wall of said shell.
- the second core remains hollow after said first core is filled with said structural engi ⁇ neered foam.
- a fabric is integrally molded with the shell.
- the fabric is arranged with the blow molding cavity such that a rear surface thereof faces the resin parison and a front surface faces away from the parison such that upon blow molding, the resin parison within said cavity of said mold the shell is formed of resilient plastic material integrally molded and bonded directly to said rear surface of the fabric.
- the fabric is bonded to the opposing wall of said shell.
- the fabric may take the form of a carpet, decorative vinyl covering, cloth, or other cosmetic covering.
- Figure 1 is a fragmentary perspective view of a passenger compartment of an automotive vehicle incor ⁇ porating structural interior trim parts in accordance with the invention
- Figure 2 is a cross sectional view of a B- pillar taken along lines 2-2 shown in figure 1;
- Figure 3 is a cross-sectional view taken along lines 3-3 shown in figure 2;
- Figure 4 is a cross-sectional view of a rear quarter panel taken along lines 4-4 shown in figure 1;
- Figure 5 is a cross sectional view of a windshield garnish molding taken along lines 5-5 shown in figure 1;
- Figure 6 is a cross section view of a door panel taken along lines 6-6 shown in figure 1;
- Figure 7 is a view showing textile material arranged within a blow molding cavity and receiving a parison
- Figure 8 is a view similar to figure 7 showing closure of the mold and blowing the parison against the textile material and mold walls;
- Figure 9 illustrates the filling of a first core within the blow molded shell with structural foam material.
- an automotive vehicle 10 has a passenger compartment 12.
- the struc ⁇ tural exterior of the automotive vehicle has various parts that surround and form a cage about the passenger compartment 12. Some of these parts are commonly referred to as the A-pillar 14, B-pillar 16, rear quarter sail 18, door panel 20, roof panel 21, and wind ⁇ shield header 22.
- structural interior trim parts 30 that cover and conceal the exterior parts 14, 16, 18, 20, 21, and 22 from within the passenger compartment 12.
- the use of structural interior trim parts 30 are used for cosmetic purposes as well as sound insulation. More specifically, the structural interior trim parts 30 may take various shapes and be secured about various parts of the passenger compartment 12.
- knee bolster 32 may be installed under the air bag assembly 24 within instrument panel 26.
- Part 34 may be installed along the A-pillar 14.
- Part 36 may be installed along B-pillar 16.
- Part 38 may be installed at the rear quarter sail 18.
- Part 39 may be installed along windshield header 22 which has particularly applicabili- ty in convertible models.
- Interior door panel 40 may be installed within door panel 20.
- Each of these struc ⁇ tural parts will have specific dimensions and shapes but all have common features as generically described for the structural trim parts 30.
- Other interior trim parts such as head liner 33 and upper seat back portion 35 may also be made in accordance with the teachings described below.
- the part 36 includes a shell 42 blow molded from poly-propylene.
- the shell may have a wall thickness of approximately 60/1000 inches.
- the part has an exterior facing wall 44 that conforms to automotive body-in-white and remaining walls 46, 48, 50, 52 and 54 that conform to a desired shape.
- the exterior facing wall 44 may have a groove 56 therein that form partition 58.
- Wall 48 has an opening 61 therein that allows the interior first section 62 to be filled with a structurally engineered foam 64.
- Interior section 62 is to be positioned above the DLO or daylight opening level 66 of the automotive passenger compartment 12 where impact with an occupant is possible during a collision.
- a second groove 70 forms a struc- tural partition 72 to provide additional structure along interior sections 68 and 69. These sections 68 and 69 remain hollow and are sealed from access to the foam 64 within section 62 by partition 58.
- the wall 46 can be formed flat or contoured and can conceal the grooves 56 and 70 from the viewpoint from within the passenger compartment 12.
- a lower section of passenger compartment facing wall 46 may have a carpet 74 and other type of fabric covering 76 directly bonded thereto.
- the coverings 74 and 76 are integrally molded with the shell 42 directly adhering and integrating itself with the backing or back surface 77 of the carpeting 74 or fabric 76 respectively.
- Figures 7, 8 and 9 illustrate one way that the part may be manufac ⁇ tured.
- a blow molding cavity is formed by a pair of mold parts 81 and 82 shown in the open position in figure 7 and in the closed position in figure 8. Mold part 81 has a contour provided by inside surface 83 that provides the desired contour of wall 46 and parts of walls 48, 50, 52 and 54.
- Mold part 82 has several upstanding areas 86 and 88 that form the grooves 58 and 70.
- a piece of carpet 74 and fabric 76 may be sewn together along seam 78 and positioned in mold 8.1 such that its front surface 79 abuts contoured surface 83.
- a poly-propylene resin parison 85 also interposed between the two mold parts 81 and 82.
- Fabric is defined in a generic sense to be any surface decorated trim, for example but not limited to a vinyl covering, a textile, simulated wood grain plastic trims or paint films. Backing of all fabric would have a coating to withstand the molding cycle without discoloration or crushing of the fabric pile in the case of carpeting.
- the materials 76 and 74 are properly chosen so that they can be stretchable in two direction so that they can deform considerably from a plane to accommodate a wide variety of contours 13.
- Parison 85 is also stretchable and deformable, in its plasticized and blow moldable state, so that it can conform to the interior of molded parts 81 and 82 upon exertion of approximately 80 psi.
- the parison 85 can be pigmented to be a desired color and surface 83 may be embossed to form a textured pattern on wall 46.
- a nozzle 63 may enter the opening 61.
- the nozzle provides the shell interior section 62 with a structural plastic foam 64.
- the nozzle is loosely fitted within opening 61 to allow air to escape as the foam 64 fills the interior section 62.
- the foam 64 fills the section 62, it is left to cure.
- the foam is structurally engineered to be substantially self supportive below a certain predetermined compressive force and becomes compressible above the predetermined force to absorb energy.
- Such predetermined force is set between what is normally encountered during everyday usage of the automotive vehicle and what an impact during collision condition produces.
- Such family of structurally engineered foams is commercially available from various sources such as Dow or BASF or such other chemical companies.
- the specific foam may vary depending on various factors such as the specific trim part 30 to which the foam is applied, and the size and type of automotive vehicle.
- the shell thickness also may be varied depending on the thickness of the interior foam, the position of the part in the vehicle, the structure of the part, and the size and type of automotive vehicle in which the trim part is installed. It is foreseen that with thicker foam interiors, the shell wall thickness can be reduced.
- the part 36 may be provided with an access port 92 for the insertion therethrough for a seat belt (not shown) .
- the port 92 may be cut into the part 36 and provided with a sleeve (not shown) fitted in port 92 or molded therein during the molding process.
- the use of structurally engineered foam 64 within the shell and the use of structural supporting partitions 58 and 72 allow the shell wall 46 to be thinner than similar plastic parts found in the prior art with similar design criteria.
- the thinner wall allows more flexibility of wall 46 upon impact forces which allow the wall 46 to flex as the foam 64 also compresses and absorbs energy. This reduces the risk of the plastic shell 42 shattering and hence reduces the risk of injury due to any such shattered plastic.
- Each of the parts 32, 34, 36, 38 and 40 may be constructed by the same method and in the same fashion as the part 46.
- the knee bolster 32 as shown in figures 1 may have its shell 42a entirely filled with foam 64 and anchored under instrument panel 26 against its front wall 44a.
- Rear quarter sail part 38 as shown in figures 1 and 4 may have its shell 42b completely filled with foam 64 and has its outer wall 44b abutting the rear quarter sail exterior steel panel 18 of the automotive vehicle.
- Windshield header part 39 as shown in figures 1 and 5 may have its shell 42c completely filled with foam 64 and has its exterior wall 44c abut the wind- shield header 22.
- Interior door panel 40 as shown in figures 1 and 6 may have its shell 42d partially filled with foam 64 within section 62d and has lower section 68d remain ⁇ ing hollow.
- Structural partition 72d may also act as the divider for retaining the foam within section 62d and from section 68d.
- the lower section of wall 46d may be integrally formed and bonded with fabric material 76.
- Seat back portion 35 may form part of the structural frame 27 of a seat back and be within the seat 37 embedded within the seating cushion and cover assembly 29.
- Each of the above described trim parts 30 may have appropriate snap fit fasteners 94 welded to the exterior wall 44 or molded internally in the mold for attachment to the shell to provide appropriate mounting of the shell within the passenger compartment.
- flanges (not shown) may be incorporated in the shell to receive fasteners therethrough.
- compatible foam such as poly- urethane with a compatible shell of polyurethane pro- vides that the foam adheres by chemical bond together which provides integrity during collision impact forces exerted thereon.
- the above described parts are illustrative of the application of the interior trim part 30 formed with the above described method and provided impact energy absorption through the use of structurally rigid foam filling 64 placed within a thin flexible shell that is shatter resistant during flexing upon impact forces of the nature and magnitude endured during collisions of automotive vehicles.
Abstract
Description
Claims
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE4397685T DE4397685T1 (en) | 1993-11-19 | 1993-11-19 | Blow molded automotive interior trim components |
US08/193,012 US5700050A (en) | 1993-11-19 | 1993-11-19 | Blow molded structural interior automotive parts |
PCT/US1993/011288 WO1995013938A1 (en) | 1993-11-19 | 1993-11-19 | Blow molded structural interior automotive parts |
AU59833/94A AU5983394A (en) | 1993-11-19 | 1993-11-19 | Blow molded structural interior automotive parts |
JP7514410A JPH09505013A (en) | 1993-11-19 | 1993-11-19 | Blow molding structure car interior parts |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PCT/US1993/011288 WO1995013938A1 (en) | 1993-11-19 | 1993-11-19 | Blow molded structural interior automotive parts |
Publications (1)
Publication Number | Publication Date |
---|---|
WO1995013938A1 true WO1995013938A1 (en) | 1995-05-26 |
Family
ID=22237204
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US1993/011288 WO1995013938A1 (en) | 1993-11-19 | 1993-11-19 | Blow molded structural interior automotive parts |
Country Status (4)
Country | Link |
---|---|
JP (1) | JPH09505013A (en) |
AU (1) | AU5983394A (en) |
DE (1) | DE4397685T1 (en) |
WO (1) | WO1995013938A1 (en) |
Cited By (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0691259A3 (en) * | 1994-07-08 | 1997-05-07 | Ford Motor Co | Energy absorbing vehicle pillar structure |
EP0791450A1 (en) * | 1996-02-23 | 1997-08-27 | Lear Corporation | Method and apparatus for joining carpet and plastic |
DE19634246A1 (en) * | 1996-08-25 | 1998-02-26 | Moeller Plast Gmbh | Trim part, in particular for sheet metal support parts in motor vehicles |
DE19644075A1 (en) * | 1996-08-25 | 1998-05-28 | Moeller Plast Gmbh | Lining or filling component, e.g. for motor vehicle body manufacture |
GB2322342A (en) * | 1997-01-03 | 1998-08-26 | Fehrer F S Gmbh & Co Kg | Energy absorbing lining element for vehicles |
US5885515A (en) * | 1997-03-06 | 1999-03-23 | Lear Corporation | Blow molding process |
GB2339174A (en) * | 1998-06-17 | 2000-01-19 | Rover Group | Bolster panel |
US6444149B1 (en) | 1997-03-10 | 2002-09-03 | Perstorp Ab | Process for the manufacturing of an article of plastic material |
WO2005030469A1 (en) * | 2003-09-30 | 2005-04-07 | Salflex Polymers Ltd. | Method for molding running board with step plate |
WO2012094719A1 (en) | 2011-01-12 | 2012-07-19 | Salflex Polymers Ltd. | Hollow article with pillar structural members |
CN103158509A (en) * | 2011-12-09 | 2013-06-19 | 丰田纺织株式会社 | Shock absorber assembly |
EP2949445A1 (en) * | 2014-05-27 | 2015-12-02 | Nhk Spring Co., Ltd. | Vehicle seat |
US9545953B2 (en) | 2013-11-18 | 2017-01-17 | GM Global Technology Operations LLC | Instrument panel for a vehicle, vehicle comprising the instrument panel, and method for producing the instrument panel |
Citations (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3836192A (en) * | 1968-05-17 | 1974-09-17 | Daimler Benz Ag | Body for vehicles, especially passenger motor vehicles |
US4045076A (en) * | 1976-03-29 | 1977-08-30 | Portland Wire & Iron Works | System for removably securing sound-proofing material to a construction vehicle |
US4229036A (en) * | 1978-02-10 | 1980-10-21 | Nissan Motor Company, Limited | Pillar garnish |
US4934736A (en) * | 1988-03-04 | 1990-06-19 | Marinus Huisman | Knee restraining device |
DE3932121A1 (en) * | 1989-09-27 | 1991-04-04 | Porsche Ag | Soft foam filling of vehicle bodywork to reduce noise - in which two=part polyurethane foam with filler is injected into cavities adjacent noisy elements |
US5040335A (en) * | 1991-03-18 | 1991-08-20 | Davidson Textron Inc. | Inner panel assembly with integral energy absorber |
US5111619A (en) * | 1991-08-12 | 1992-05-12 | General Motors Corporation | Door trim panel retaining assembly |
US5141279A (en) * | 1991-09-23 | 1992-08-25 | Davidson Textron Inc. | Side impact protection apparatus |
US5171058A (en) * | 1989-06-30 | 1992-12-15 | Mazda Motor Corporation | Collision energy absorbing structure for a vehicle side body |
-
1993
- 1993-11-19 JP JP7514410A patent/JPH09505013A/en active Pending
- 1993-11-19 AU AU59833/94A patent/AU5983394A/en not_active Abandoned
- 1993-11-19 WO PCT/US1993/011288 patent/WO1995013938A1/en active Application Filing
- 1993-11-19 DE DE4397685T patent/DE4397685T1/en not_active Withdrawn
Patent Citations (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3836192A (en) * | 1968-05-17 | 1974-09-17 | Daimler Benz Ag | Body for vehicles, especially passenger motor vehicles |
US4045076A (en) * | 1976-03-29 | 1977-08-30 | Portland Wire & Iron Works | System for removably securing sound-proofing material to a construction vehicle |
US4229036A (en) * | 1978-02-10 | 1980-10-21 | Nissan Motor Company, Limited | Pillar garnish |
US4934736A (en) * | 1988-03-04 | 1990-06-19 | Marinus Huisman | Knee restraining device |
US5171058A (en) * | 1989-06-30 | 1992-12-15 | Mazda Motor Corporation | Collision energy absorbing structure for a vehicle side body |
DE3932121A1 (en) * | 1989-09-27 | 1991-04-04 | Porsche Ag | Soft foam filling of vehicle bodywork to reduce noise - in which two=part polyurethane foam with filler is injected into cavities adjacent noisy elements |
US5040335A (en) * | 1991-03-18 | 1991-08-20 | Davidson Textron Inc. | Inner panel assembly with integral energy absorber |
US5111619A (en) * | 1991-08-12 | 1992-05-12 | General Motors Corporation | Door trim panel retaining assembly |
US5141279A (en) * | 1991-09-23 | 1992-08-25 | Davidson Textron Inc. | Side impact protection apparatus |
Cited By (22)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0691259A3 (en) * | 1994-07-08 | 1997-05-07 | Ford Motor Co | Energy absorbing vehicle pillar structure |
EP0791450A1 (en) * | 1996-02-23 | 1997-08-27 | Lear Corporation | Method and apparatus for joining carpet and plastic |
DE19634246A1 (en) * | 1996-08-25 | 1998-02-26 | Moeller Plast Gmbh | Trim part, in particular for sheet metal support parts in motor vehicles |
DE19644075A1 (en) * | 1996-08-25 | 1998-05-28 | Moeller Plast Gmbh | Lining or filling component, e.g. for motor vehicle body manufacture |
DE19644075B4 (en) * | 1996-08-25 | 2004-09-09 | Möller Plast GmbH | Cladding part, in particular for sheet metal support parts in motor vehicles |
GB2322342A (en) * | 1997-01-03 | 1998-08-26 | Fehrer F S Gmbh & Co Kg | Energy absorbing lining element for vehicles |
US5885515A (en) * | 1997-03-06 | 1999-03-23 | Lear Corporation | Blow molding process |
US6444149B1 (en) | 1997-03-10 | 2002-09-03 | Perstorp Ab | Process for the manufacturing of an article of plastic material |
GB2339174A (en) * | 1998-06-17 | 2000-01-19 | Rover Group | Bolster panel |
US7332120B2 (en) | 2003-09-30 | 2008-02-19 | Salflex Polymers Ltd. | Method for molding running board with step plate |
WO2005030469A1 (en) * | 2003-09-30 | 2005-04-07 | Salflex Polymers Ltd. | Method for molding running board with step plate |
WO2012094719A1 (en) | 2011-01-12 | 2012-07-19 | Salflex Polymers Ltd. | Hollow article with pillar structural members |
CN103379990A (en) * | 2011-01-12 | 2013-10-30 | 索尔弗莱克斯聚合物有限公司 | Hollow article with pillar structural members |
CN103379990B (en) * | 2011-01-12 | 2015-09-30 | 索尔弗莱克斯聚合物有限公司 | There is the hollow object of corbeling component |
US9174382B2 (en) | 2011-01-12 | 2015-11-03 | Salflex Polymers Ltd. | Hollow article with pillar structural members |
US10357934B2 (en) | 2011-01-12 | 2019-07-23 | Abc Technologies Inc. | Hollow article with pillar structural members |
CN103158509A (en) * | 2011-12-09 | 2013-06-19 | 丰田纺织株式会社 | Shock absorber assembly |
CN103158509B (en) * | 2011-12-09 | 2015-07-01 | 丰田纺织株式会社 | Shock absorber assembly |
US9545953B2 (en) | 2013-11-18 | 2017-01-17 | GM Global Technology Operations LLC | Instrument panel for a vehicle, vehicle comprising the instrument panel, and method for producing the instrument panel |
EP2949445A1 (en) * | 2014-05-27 | 2015-12-02 | Nhk Spring Co., Ltd. | Vehicle seat |
CN105313734A (en) * | 2014-05-27 | 2016-02-10 | 日本发条株式会社 | Vehicle seat |
US9718385B2 (en) | 2014-05-27 | 2017-08-01 | Nhk Spring Co., Ltd. | Vehicle seat |
Also Published As
Publication number | Publication date |
---|---|
AU5983394A (en) | 1995-06-06 |
JPH09505013A (en) | 1997-05-20 |
DE4397685T1 (en) | 1996-11-14 |
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