Automotive interior trim assembly and pad insertion

Abstract

A trim assembly comprises a substrate member including a moveable panel integrally formed in the substrate and moveable between an open and closed position. A flexible skin overlies at least a portion of the substrate member and is integrally coupled to the substrate. The substrate and flexible skin are configured to define a cavity having an opening. The cavity opening is accessible when the moveable panel is in the open position. A resilient foam pad is positioned within the cavity to provide a soft feel to the trim assembly. The foam pad is inserted into the cavity using a tool that pulls a vacuum and compresses the foam pad. The foam pad is inserted into the cavity and the vacuum is released thereby expanding the foam pad to fill the cavity. The tool is removed and the moveable panel is moved to and secured in the closed position.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application is a divisional of U.S. application Ser. No. 10 / 708,561, filed Mar. 11, 2004 The disclosure of which is hereby incorporated by reference herein. [0002] The present invention is also related to U.S. Ser. No. 10 / 709,698, filed May 24, 2004; U.S. Ser. No. 10 / 710,497, filed Jul. 15, 2004; and U.S. Ser. No. 10 / 710,499, filed Jul. 15, 2004.FIELD OF THE INVENTION [0003] The present invention pertains generally to automotive interiors and more particularly to trim assemblies for automotive interiors. BACKGROUND OF THE INVENTION [0004] It is known to provide automotive interiors with various trim assemblies to improve the aesthetic appearance of the automotive interior and for the comfort and convenience of vehicle occupants. Examples of these interior trim assemblies include the instrument panels, armrests, door trim panels and consoles. For example, armrests are typically secured to a vertical panel of the automotive interior ...

AI Technical Summary

Benefits of technology

The present invention provides an automotive interior trim assembly that is soft to the touch, but can be produced efficiently and cost-effectively. The trim assembly includes a substrate member and a flexible skin covering the substrate. A cavity is formed between the substrate and the flexible skin, and a resilient foam pad is positioned within the cavity to provide a soft feel. The foam pad is inserted into the cavity using a vacuum insertion tool, which causes the foam pad to compress and expand to snugly fill the cavity. The moveable panel is then positioned and secured in the closed position to enclose the foam pad. The technical effects of this invention include a soft feel to the trim assembly, efficient and cost-effective production, and improved comfort and safety for the automotive interior.

Problems solved by technology

These prior methods are generally costly due to the multiple components and manufacturing steps required to make the padded trim assemblies.

Inserting the pad material into trim assemblies and securing the pad material and pad carrier therein requires additional components that increase the overall manufacturing cost of the trim assemblies.

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