Method for producing a vehicle interior component

Abstract

A method for producing a vehicle interior component can include heating a polymeric material to a molten state to produce a molten polymer. The molten polymer can be extruded to form more than one molten polymer filament. A fastening device can be inserted into the molten polymer, and the molten polymer can be cooled in a fluid bath to produce a consolidated filament structure to which the fastening device is secured.

Description

[0001] Cross Reference to Related Applications

[0002] This application claims the benefit of Danish Patent Application No. PA202370026, filed January 19, 2023, which in turn claims the benefit of U.S. Provisional Application Serial No. 63 / 356,249, filed June 28, 2022, the disclosures of both of which are hereby incorporated by reference in their entireties. TECHNICAL FIELD

[0003] The present disclosure relates to a method and an apparatus for producing a vehicle interior component. BRIEF DESCRIPTION OF DRAWINGS

[0005] Figure 1 A schematic illustration of a system and method according to embodiments described herein is shown;

[0006] Figure 2 A schematic illustration of an embodiment of a part of the method shown in Figure 1

[0007] Figure 3 A schematic illustration of a fastening arrangement that can be used with the method shown in Figure 2

[0008] A schematic illustration of an embodiment of a part of the method shown in Figure 4 Figure 1

[0009] Figure 5 A secondary extrusion head that can be used as part of a system and method according to embodiments described herein is shown;

[0010] Figure 6 A consolidated filament structure according to embodiments described herein is shown, with a fastening arrangement secured to the consolidated filament structure;

[0011] Figure 7 A schematic illustration of an embodiment of a part of the method shown in Figure 1

[0012] Figures 8A-8C A schematic illustration of a step that can be performed in the embodiment shown in Figure 7

[0013] DETAILED DESCRIPTION

[0014] ​​​​​Reference will now be made in detail to implementations, examples of which are illustrated in the accompanying drawings. In the following detailed description of implementations, numerous specific details are set forth in order to provide a thorough understanding of the various implementations described herein. However, it will be apparent to one skilled in the art that the implementations described herein can be practiced without these specific details. In other instances, well-known methods, procedures, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the implementations.

[0015] It is to be understood that the disclosed implementations are merely examples and that other forms and alternatives can be possible. The drawings are not necessarily to scale; some features can be exaggerated or minimised in order to show details that are characteristic of specific embodiments. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the implementations according to the disclosure.

[0016] “one or more” includes a function performed by one element, a function performed by more than one element (e.g., in a distributed manner), several functions performed by one element, several functions performed by several elements, or any combination of the above.

[0017] It should also be understood that, although the terms first, second, etc. are used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first contact could be termed a second contact, and, similarly, a second contact could be termed a first contact, without departing from the scope of the described implementations. The first contact and the second contact are both contacts, but they are not the same contact.

[0018] The terminology used in the description of the implementations herein is for the purpose of describing particular implementations only and is not intended to be limiting. As used in the description of the implementations and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “including” as used herein, specifies the presence of features, integers, steps, operations, elements, or components, but does not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, or groups thereof.

[0019] As used herein, the term "if' is optionally construed to mean "when" or "when a' or "in response to determining" or "in response to detecting," depending on the context. Similarly, the phrase "if it is determined" or "if [a stated condition or event] is detected" is optionally construed to mean "upon determining" or "in response to determining" or "upon detecting [the stated condition or event]" or "in response to detecting [the stated condition or event]," depending on the context.

[0020] Reference is made to Figure 1 A schematic view of a system 10 that can be used with a method 11 according to embodiments described herein is shown. A hopper 12 houses solid pellets of a polymeric material 14 to be extruded. In this embodiment, the material 14 is linear low density polyethylene (LLDPE), although the methods described herein can be used to produce finished products from different types of polymers as desired and effective. The material 14 is fed from the hopper 12 to an extruder 16. The extruder 16 melts the material 14 and conveys the material 14 to a die plate assembly 18 that includes a die plate 20. The extruder 16 can be a conventional extruder, for example, that includes a barrel that receives a rotatable screw. Rotation of the screw forces the material 14 to move through the barrel and helps to heat the material due to friction generated as the screw rotates. Heating elements can be disposed on the barrel and heat the polymeric material 14 within the barrel.

[0021] The material 14 exits the extruder 16 at a location 22 under pressure and in a molten state. Unless otherwise indicated, the term "molten" as used herein means that the material is at least partially molten. This does not mean that the material must be in a completely liquid state; rather, it means that the material is not completely solid and is still able to flow through the elements of the system 10. For example, a molten material is still able to flow through the die plate 20, but it can be very viscous and begin to solidify. Once the solid pellets of polymeric material 14 are melted in the extruder 16, the material will begin to cool as it stops being agitated by the extruder screw and moves away from any heaters. At different points in the process 11, the material can have a higher or lower viscosity, but the term "molten" applies herein if it is still partially molten and able to flow— even slowly.

[0022] The die plate 20 extrudes the material 14 into a filament 24. More specifically, the die plate 20 has a plurality of holes disposed therethrough (see, e.g., FIG. 2) that are aligned with the extruder 16. The holes in the die plate 20 are shaped to form the filament 24. The filament 24 is then cooled and solidified as it is drawn away from the die plate 20. Figure 2), the molten material 14 passes through the holes. A single filament 24 is extruded from each of the template holes. The filaments 24 fall downward from the template 20 under the influence of system pressure and gravity to a hopper 26. The hopper 26 helps to consolidate or group the filaments 24 into a more compact arrangement, the filaments 24 bend or coil in the hopper 26, and each filament 24 contacts and bonds to at least one other filament 24. In this embodiment, the hopper 26 has a hopper inlet 28 and a hopper outlet 30 that is smaller than the hopper inlet 28. More specifically, the hopper 26 is narrower at the hopper outlet 30 than at the hopper inlet 28. The individual, separate filaments 24 enter the hopper inlet 28, then the filaments 24 bend or coil and move into contact with each other as they accumulate and slide down the hopper 26 toward the hopper outlet 30, and the consolidated filament structure 32 exits the hopper outlet 30 and enters a water tank 34. As the filaments 24 reach the hopper 26, those filaments near the outer portions of the hopper 26— about 2 to 3 rows— slide down the angled surface of the hopper 26, which creates a skin on the consolidated filament structure 32.

[0023] The water tank 34 contains water 36 and receives the consolidated filament structure 32 from the hopper 26. The water 36 performs at least two functions. First, it helps to temporarily support the consolidated filament structure 32 to prevent it from collapsing or compacting into a less open or less porous arrangement. Thus, the water 36 provides some resistance that causes additional bending and coiling of the filaments 24 to further build the consolidated filament structure 32. Second, the water 36 cools the polymer filaments 24 from the outside to solidify them. The temperature of the water 36 can be much lower than the temperature of the filaments 24 when they exit the template 20, for example, the water can be at the temperature of the ambient environment surrounding the tank 34. Although liquid water 36 is used in this embodiment, other types of fluids can be used in other embodiments.

[0024] The water tank 34 includes a variety of rollers and conveyors that help to move the consolidated filament structure 32 through and out of the water 36. A traction conveyor 38 is submerged in the water 36 and engages opposite sides of the consolidated filament structure 32 to move the consolidated filament structure 32 away from the hopper 26 at approximately the same speed that the consolidated filament structure 32 exits the hopper 26. The gap between the opposite portions of the traction conveyor 38 is slightly narrower than the width of the consolidated filament structure 32 to allow the traction conveyor 38 to better grip the consolidated filament structure 32. As previously mentioned, Figure 1 is a schematic representation and has been simplified for purposes of illustration. For example, conveyors such as the traction conveyor 38 can be positioned toward the front and rear of the system 10 as they are oriented in Figure 1 , rather than on the left and right sides as shown.

[0025] Another roller 40 helps keep the bonded filament structure 32 submerged and helps guide it through the water 36 toward the conveyor belt 42 and vibrating table 44 located outside the water tank 34. While the bonded filament structure 32 is on the conveyor belt 42, the vibrating table 44 vibrates the bonded filament structure 32 to remove at least some of the water 36. Pressurized air can also be blown onto the bonded filament structure 32, and the bonded filament structure 32 can also be squeezed to remove more water 36. Finally, the bonded filament structure 32 can be cut to the desired size and shape. As described above, the bonded filament structure 32 forms a stranded-mesh material, which can be used, for example, as a lining blank for part of a vehicle interior component. In some cases, the bonded filament structure 32 can have a rectangular cross-section, which is subsequently cut or shaped into a desired profile for its intended use.

[0026] Figure 2 A system, such as system 10, is shown as a portion of an embodiment of the methods described herein. More specifically, Figure 2 A template 46 is shown, which has more than one hole disposed therethrough for extruding molten polymer into more than one molten polymer filament 48. For clarity, in Figure 2 Only some molten polymer filaments 48 are marked. Similar to Figure 1 As illustrated in the diagram, molten polymer filaments 48 fall from a template 46 toward a funnel device 50. Once they have passed through the funnel device 50, the molten polymer filaments 48 enter a fluid tank 52, where they are introduced into a fluid bath. In this embodiment, the fluid tank 52 contains water 54. (As shown above...) Figure 1 As described, fluid baths are particularly used for cooling molten polymers. Figure 2 The step of introducing the fastening device 56 into the molten polymer is also shown. In this step, the fastening device 56 is inserted into or combined with the molten polymer. In this embodiment, the fastening device 56 is introduced into the molten polymer after the molten polymer filament 48 has been formed. In other embodiments, as explained in more detail below, the fastening device, such as the fastening device 56, can be introduced into the molten polymer as it is extruded through a template (i.e., through the same template that forms the molten polymer filament 48).

[0027] like Figure 2As shown, the fastening device 56 includes a strand portion 58 configured as an elongated member. The fastening device 56 may include plastic beads, fabric (e.g., duon), or it may be a string, rope, or other similar structure. When using this type of fastening device, it can provide fixation, for example, to a decorative cover or other materials such as loops, clips, etc., of a bonded filament structure to be positioned on the resulting product. (As in combination...) Figure 3 To explain in more detail, fastening device 56 may include more than one discrete fastener. The strand portion 58 may have a defined length, and in particular, be long enough to accommodate the resulting product (such as...). Figure 1 The defined length of the consolidated filament structure 32) shown in the figure. Figure 2 In the embodiment shown, the fastening device 56, and more particularly the strand portion 58, is continuously inserted into the molten polymer over at least a portion of its defined length. In this embodiment, it is continuously inserted from a spool 60, which rotates as indicated by the directional arrow 62.

[0028] As described above, fastening devices such as fastening device 56 may include, for example, fastening devices such as... Figure 3 The schematic diagram shows more than one discrete fastener. Figure 3 In the embodiment shown in the figure, the fastening device 64 includes a strand portion 66, which forms an elongated member of the fastening device 64. Figure 3 The fastening device 64 shown can be a much longer segment of the structure. In addition to the strand portion 66, the fastening device 64 includes more than one discrete fastener 68, which can be, for example, a Christmas tree fastener, a clip, a thumbtack, etc. Because the fasteners 68 are attached to the strand portion 66, which is continuously supplied to the molten polymer, the fasteners 68 are introduced and inserted into the molten polymer at a predetermined frequency defined by the distance between the fasteners 68 and the rate at which the fastening device 64 is inserted into the molten polymer.

[0029] Fasteners 68 are also introduced and inserted into the molten polymer at predetermined positions, which can also be defined by the distance between the fasteners 68 and the rate at which the fastening device 64 is introduced into the molten polymer. The position of the fasteners 68 relative to the molten polymer filaments 48 can also be determined by the position of the fasteners 68 when they are inserted into the molten polymer. For example, in Figure 2 In the embodiment illustrated, the fastening device 56 is inserted very close to one edge of the molten polymer filament 48. This can produce an finished product with the fastening device 56 very close to one surface, making it easily accessible for attachment to other products.

[0030] Figure 4A system, such as system 10, is also shown as a component of an embodiment of the methods described herein. More specifically, Figure 4 A template 70 is shown, having more than one hole disposed therethrough for extruding molten polymer into more than one molten polymer filament 72. For clarity, in... Figure 4 Only some molten polymer filaments 72 are marked. Similar to... Figure 1 The process illustrated in the diagram involves molten polymer filament 72 falling from a template 70 and being received by a funnel device 74. Once introduced into and passed through the funnel device 74, the molten polymer filament 72 enters a fluid tank 76, which in this embodiment contains water 78. The fastening device 80 includes a strand portion 82, which may be similar to... Figure 2 The strand section 58 shown in the figure Figure 3 The section 66 shown in the image. Figure 4 In the embodiment shown, the fastening device 80 is introduced into the molten polymer through a larger orifice 84 in the template 70, which can be referred to as a "co-extrusion" technique. As the molten polymer is extruded into molten polymer filaments 72, the strand portions 82 can be continuously supplied through the orifice 84.

[0031] Figure 1 The secondary extrusion head 85 is shown in dashed lines, through which the fastening device 80 can be introduced under the template 20. Figure 5 The image shows a bottom view of the secondary extrusion head 85, which is juxtaposed with the template 20. (See image for details.) Figure 5 As shown, fastening devices such as fastening device 80 can be introduced through secondary extrusion head 85, and in particular through hole 87.

[0032] The fastening device does not include discrete fasteners (such as...) Figure 3 In the application of the fastener 68 shown, the strand portion 82 can be inserted through a standard hole in the template 70. Alternatively, a special inlet tube can be inserted through the template 70 to accommodate a fastening device with discrete fasteners having a hole larger than the standard template hole. Figure 6 A portion of a bonded filament structure 86 is shown, to which a fastening device 88 is attached. The fastening device 88 includes strand portions 90 attached to the bonded filament structure 86. More specifically, the fastening device 88 is secured to the filament 92 by placing it in contact with the filament 92 while it is still in a molten state (for clarity, in...). Figure 6 Only some filaments 92 are marked in the middle, so that when the filaments 92 cool, they form a strong bond.

[0033] exist Figure 7 The diagram illustrates a portion of a system, such as system 10. More specifically,Figure 7 A template 94 is shown, having more than one hole disposed therethrough for extruding molten polymer into more than one molten polymer filament 96. For clarity, in... Figure 7 Only some polymer filaments 96 are marked. Molten polymer filaments 96 fall from template 94, where they are introduced into funnel device 98. After leaving funnel device 98, the polymer filaments 96 enter fluid tank 100, which in this embodiment contains water 102. Figure 7 In the embodiment shown, the fastening device can be introduced into the molten polymer filament 96 via the funnel device 98. Figure 7 Isolated details in Figure 8A A magnified view is shown. A schematic diagram of the process of inserting the fastening device into the molten polymer filament 96 via the funnel device 98 is shown in [the diagram]. Figure 8B and Figure 8C As shown in the image.

[0034] exist Figure 8A The figure shows part 104 of the funnel device 98. (As shown in the image...) Figure 8A As shown, portion 104 of the funnel device 98 prevents the fastening device 106 from being introduced into the molten polymer filament 96. Figure 6 and Figure 7 In the embodiment shown, portion 104 of the funnel device 98 is movable to allow the fastening device 106 to be combined with the molten polymer filament 96. This is in Figure 8B The middle diagram shows that portion 104 of the funnel device 98 has been moved to the left as indicated by directional arrow 108. This allows the fastening device 106 to move downwards as illustrated by directional arrow 110. Figure 8B and Figure 8C In this embodiment, for clarity, the molten polymer filament 96 has been removed. Once the fastening device 106 is introduced into the molten polymer filament 96, portion 104 of the funnel device 98 is moved back to its original position, as indicated by directional arrow 112. This embodiment allows discrete fasteners to be individually placed in contact with the molten polymer filament 96 at predetermined frequencies and predetermined locations.

[0035] While exemplary embodiments have been described above, this does not mean that these embodiments describe all possible forms according to this disclosure. In this regard, the language used in this specification is descriptive rather than restrictive, and it should be understood that various changes can be made without departing from the spirit and scope of this disclosure. Furthermore, features of various implementation embodiments can be combined to form other embodiments according to this disclosure.

Claims

1. A method for producing interior parts for a vehicle, comprising: The polymer material is heated to a molten state, so that the polymer material becomes a molten polymer; The molten polymer is introduced into a template having more than one hole disposed therethrough, such that the molten polymer moves through the hole and forms more than one molten polymer filament; A fastening device is introduced into the molten polymer, the fastening device comprising a strand portion and more than one discrete fastener attached to the strand portion; as well as After the molten polymer leaves the template, the molten polymer is cooled to form a solidified filament structure and the fastening device is fixed to the solidified filament structure.

2. The method of claim 1, wherein the fastening device is introduced into the molten polymer after the molten polymer is introduced into the template.

3. The method of claim 1, wherein the fastening device is introduced into the molten polymer through the template.

4. The method of claim 1, wherein the strand portion has a length, and the strand portion is continuously introduced into the molten polymer over at least a portion of the length.

5. The method of claim 1, wherein the more than one discrete fastener is introduced into the molten polymer at a predetermined frequency.

6. The method of claim 1, wherein cooling the molten polymer comprises introducing the molten polymer into a fluid bath, the method further comprising receiving the molten polymer with a funnel device before introducing the molten polymer into the fluid bath, and wherein the more than one discrete fastener is introduced into the molten polymer through the funnel device.

7. A vehicle interior component manufactured by the method according to any one of claims 1-6, comprising a bonded polymer filament structure and a fastening device bonded to the bonded polymer filament structure, wherein the fastening device comprises a strand portion and more than one discrete fastener attached to the strand portion.

8. A method for producing interior parts for a vehicle, comprising: Heating polymer materials to a molten state to produce molten polymer; The molten polymer is extruded to form more than one molten polymer filament; A fastening device is inserted into the molten polymer, the fastening device comprising a strand portion and more than one discrete fastener attached to the strand portion; as well as The molten polymer is cooled in a fluid bath to produce a bonded filament structure to which the fastening device is fixed.

9. The method of claim 8, wherein the fastening device comprises an elongated member, and inserting the fastening device into the molten polymer comprises continuously feeding the elongated member into the molten polymer within at least a portion of the length of the elongated member.

10. The method of claim 9, wherein the elongated member comprises more than one discrete fastener.

11. The method of claim 8, wherein the more than one discrete fastener is inserted into the molten polymer at a predetermined position in the molten polymer.

12. The method of claim 11, further comprising introducing the molten polymer into a funnel device before cooling the molten polymer in the fluid bath, and wherein the fastener is inserted into the molten polymer through the funnel device.

13. The method according to any one of claims 8-11, wherein the fastening device is inserted into the molten polymer after the molten polymer is extruded to form the molten polymer filament.

14. The method according to any one of claims 8-11, wherein the fastening device is inserted into the molten polymer when the molten polymer is extruded to form the molten polymer filament.

15. The method according to any one of claims 8-11, wherein extruding the molten polymer comprises introducing the molten polymer into an extruder, and inserting the fastening device into the molten polymer comprises inserting the fastening device through a different extruder.

16. A liner blank for a vehicle interior component produced by the method according to any one of claims 8-15, the liner blank comprising a bonded polymer filament structure and fastening means bonded to the bonded polymer filament structure, wherein the fastening means comprises a strand portion and more than one discrete fastener attached to the strand portion.

17. A method for producing interior parts for a vehicle, comprising: Heating the polymer material to produce a molten polymer; More than one molten polymer filament is formed from the molten polymer; The fastening device is combined with the molten polymer, the fastening device comprising a strand portion and more than one discrete fastener attached to the strand portion; as well as The molten polymer is cooled in a fluid bath to produce a bonded filament structure to which the fastening device is fixed.

18. The method of claim 17, wherein the fastening device is combined with the molten polymer after the molten polymer filament is formed.

19. The method of claim 17, wherein the fastening device is combined with the molten polymer when the molten polymer filament is formed.

20. The method according to any one of claims 17-19, wherein the fastening device comprises an elongated member, and combining the fastening device with the molten polymer comprises continuously feeding the elongated member into the molten polymer within at least a portion of the length of the elongated member.

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