FOUR-COMPONENT ARMREST ASSEMBLY AND METHOD FOR MANUFACTURING THE SAME

Abstract

Armrest assembly (10), comprising: a carrier layer (12) with a receptacle (20); a tissue layer (14) extending over the receptacle (20), wherein the receptacle (20) includes a lower wall (24) that lies at least partially beneath the tissue layer (14); a matrix boundary layer (32) that connects the tissue layer (14) with the support layer (12), wherein the matrix boundary layer (32) comprises a part of the tissue layer (14) which is impregnated with resin of the carrier layer (12), wherein the matrix boundary layer (32) extends continuously around a circumferential edge (34) of the tissue layer (14), and wherein the lower wall (24) comprises a continuous circumferential shoulder (26) adjacent to the matrix boundary layer (32) and includes at least one support section (28) spanning the continuous circumferential shoulder (26); a cushion (16) that lies in the inlet (20) above the tissue layer (14); and a covering material (18) that conceals the padding (16) and the fabric layer (14) and seals the receptacle (20).

Description

TECHNICAL AREA

[0001] This document generally concerns the field of motor vehicle equipment and in particular a new and improved armrest assembly and a method for manufacturing the armrest assembly. GENERAL STATE OF THE ART

[0002] In the past, an armrest assembly A was manufactured from five component parts (see Fig. 1) These component parts include a carrier layer S, which is usually molded from a plastic material. A fabric frame FF is separately molded from a plastic material and attached to the carrier substrate S. A fabric layer F is then attached to the fabric frame FF. A pad C, made of foam or another suitable material, is then placed on the carrier substrate over the fabric layer F. A cover surface A, made of coating material CS, is then secured to the carrier substrate S, concealing and covering the pad C, the fabric F, and the fabric frame FF.

[0003] Prior art patent US 7,775,584 B2 describes an armrest assembly comprising a support layer with a receptacle, wherein the receptacle includes a lower wall, the lower wall comprising a continuous circumferential shoulder and at least one support section spanning the continuous circumferential shoulder, a pad that lies in the receptacle, and a covering material that conceals the pad and closes the receptacle.

[0004] This document concerns a new and improved armrest assembly comprising only four components. In particular, the separate fabric frame FF, which is present in the prior art armrest assembly, is eliminated. Fig. 1 is used. In this way, a new and improved armrest assembly eliminates the manufacturing steps of separately forming the fabric frame and attaching the fabric frame to the backing layer. Accordingly, the new and improved armrest assembly can be manufactured in a more efficient production process, which reduces production costs and production time. SUMMARY

[0005] In accordance with the tasks and advantages described herein, a new and improved armrest assembly is provided. The armrest assembly comprises a carrier layer containing a recess and a fabric layer extending over the recess. A matrix boundary layer bonds the fabric layer to the carrier layer, effectively forming an integrated armrest subassembly structure. A pad lies over the fabric layer within the recess, and a cover material conceals the pad and fabric layer while simultaneously sealing the recess. The matrix boundary layer comprises a portion of the fabric layer impregnated with a resin from the carrier layer. The matrix boundary layer extends continuously around a circumferential edge of the fabric layer.

[0006] The receptacle includes a lower wall that lies at least partially beneath the tissue layer. The lower wall includes a continuous circumferential shoulder that borders the matrix boundary layer. Furthermore, the lower wall includes at least one support section that spans the continuous circumferential shoulder. Thus, in some embodiments, the continuous circumferential shoulder and the at least one support section define a plurality of relief openings that lie beneath the tissue layer.

[0007] The armrest assembly further comprises a cushion that lies in the recess above the fabric layer, and a covering material that conceals the cushion and fabric layer and closes the recess.

[0008] Furthermore, a method for manufacturing the armrest assembly is provided below. The method can be described as comprising the steps of (a) positioning a layer of fabric in a first section of a mold, (b) closing a second section of the mold with the first section of the mold, and (c) injecting resin into the mold to form a support layer.

[0009] The process can further include the step of forming a matrix boundary layer that bonds the fabric layer to the substrate. Additionally, the process can include impregnating a portion of the fabric layer with the resin that is injected into the mold.

[0010] The process can include the step of cooling the mold to cure the resin and bond the fabric layer to the substrate at the matrix interface. The process can also include the steps of opening the mold and then removing an armrest subassembly from the mold. The armrest subassembly can comprise the substrate and the fabric layer, which are bonded together by the matrix interface.

[0011] The process may further include the step of positioning a cushion, which lies above the fabric layer, in a recess molded into the armrest substrate. The process may also include the steps of concealing the cushion and the fabric layer and sealing the recess with a covering material.

[0012] An unstressed armrest subassembly is also provided. The armrest subassembly may include a carrier layer with a recess, a fabric layer stretched over the recess, and a matrix boundary layer bonding the fabric layer to the carrier layer. The matrix boundary layer may include a portion of the fabric layer impregnated with resin from the carrier layer.

[0013] The matrix boundary layer can extend continuously around a circumferential edge of the tissue layer. The image can further include a lower wall that lies at least partially beneath the tissue layer. The lower wall can include a continuous circumferential shoulder that borders the matrix boundary layer.

[0014] The following description shows and describes several preferred embodiments of the armrest assembly. It should be noted that the armrest assembly is suitable for other, different embodiments and that its various details are suitable for modification in several obvious aspects without deviating from the armrest assembly as set forth and described in the following claim. Accordingly, the drawings and descriptions are to be considered illustrative and not limiting. BRIEF DESCRIPTION OF THE DRAWING FIGURES

[0015] The attached drawing figures, which are included here and form part of the description, illustrate several aspects of the armrest assembly, the armrest sub-assembly and the manufacturing process and, together with the description, serve to explain certain basic ideas of the same. Fig. Figure 1 is an expanded perspective view of a prior art armrest assembly comprising five separate components. Fig. Figure 2 is an expanded perspective view of the new and improved armrest assembly, which is essentially equivalent to the prior art armrest assembly. Fig. It is 1, but is made from only four components. Fig. 3 is a cross-sectional view of the assembled armrest assembly made of Fig. 2. Fig. 4 is a schematic block diagram of the process for manufacturing the armrest assembly from the Fig. 2 and Fig. 3.

[0016] A detailed reference will now be made to the present preferred embodiments of the armrest assembly and the associated manufacturing process, examples of which are shown in the accompanying drawing figures. DETAILED DESCRIPTION

[0017] Now, attention will be turned to the Fig. 2 and Fig. 3 Reference is made to the new and improved armrest assembly 10. As shown, the armrest assembly 10 comprises a support layer 12, a fabric layer 14, a padding 16, and an outer covering material 18. The support layer 12 can be formed from essentially any suitable resin material. The support layer 12 includes a receptacle 20 defined in an upright outer lip 22.

[0018] In the illustrated embodiment, the receptacle 20 includes a lower wall 24, which comprises a continuous circumferential shoulder 26 and at least one support section 28 spanning the continuous circumferential shoulder 26. In the illustrated embodiment, the lower wall 24 includes two support sections 28 spanning the continuous circumferential shoulder 26, and the support sections 28 define a plurality of relief openings 30.

[0019] The fabric layer 14 can be made of any suitable material, such as nylon fabric, that is appropriate for this application and available from various manufacturers. The fabric layer 14 extends over the receptacle 20, so that the lower wall 24 lies partially beneath the fabric layer 14.

[0020] A matrix boundary layer 32 connects the fabric layer 14 to the support layer 12. The matrix boundary layer 32 is located where the resin of the armrest support layer 12 impregnates and hardens the fabric of the fabric layer 14 to provide a secure bond that effectively makes the fabric layer and the armrest support layer 12 a one-piece armrest subassembly 35.

[0021] In the illustrated embodiment, the matrix boundary layer 32 extends continuously around a circumferential edge 34 of the tissue layer 14. As also shown in Fig. As shown in Figure 3, the continuous circumferential shoulder 26 borders the lower wall 24 matrix boundary layer 32.

[0022] The padding 16 can be made of any suitable material, including various soft foams known in the prior art to be useful for this particular application. The outer covering material 18 can be made of any suitable material known in the prior art to be useful as an armrest A-surface cover, including, for example, various fabrics, cloth, artificial leather, leather, and suitable materials with a soft feel.

[0023] It will now be on Fig. Reference is made to the process 50 for manufacturing the armrest assembly 10. This process includes the step of positioning the fabric layer 14 at a predetermined point in a first section of a mold for forming the support layer 12 (see Box 52). This is followed by closing a second section of the mold with the first section of the mold (see Box 54).

[0024] The manufacturing process then involves injecting resin into the mold to form the carrier layer 12 (see Box 56). Furthermore, the process includes forming the matrix interface layer 32, which bonds the fabric layer 14 to the carrier layer 12 (see Box 58). In the illustrated embodiment, this is achieved by impregnating the fabric layer 14 with the resin injected into the mold and cooling the mold so that the resin hardens and bonds the fabric layer to the carrier layer 12 at the matrix interface layer 32 to form the armrest subassembly 35.

[0025] The next step in the process involves opening the mold (see Box 60). This is followed by the step of removing the armrest subassembly 35 from the mold (see Box 62). As noted previously, in the illustrated embodiment, the armrest subassembly 35 comprises the support layer 12 and the fabric layer 14, which are connected to each other at the matrix interface layer 32.

[0026] The manufacturing process then includes the step of positioning the padding 16, which lies above the fabric layer 14, in the recess 20, which is molded into the carrier layer 12 (see Box 64). This is followed by the steps of concealing the padding 16 and the fabric layer 14 and closing the recess 20 with the covering material 18. The covering material 18 can be attached to the carrier layer 12 by a suitable adhesive, mechanical fasteners, or a combination of adhesive and fasteners. The completed and assembled armrest assembly 10 is in Fig. 3 shown.

[0027] As is evident from the preceding description, the new and improved armrest assembly 10 is manufactured from only four components, and the manufacturing process 50 eliminates the need to separately form a fabric frame FF and attach the fabric frame FF to the support layer S, as is the case with the armrest assembly A of the prior art. Fig. 1 is required. Advantageously, the elimination of one forming step and one assembly step significantly reduces manufacturing costs and manufacturing time, thus enabling the new and improved armrest assembly 10 to be manufactured far more efficiently.

Claims

[1] Armrest assembly (10), comprising: a carrier layer (12) with a receptacle (20); a tissue layer (14) extending over the receptacle (20), wherein the receptacle (20) includes a lower wall (24) that lies at least partially beneath the tissue layer (14); a matrix boundary layer (32) that connects the tissue layer (14) with the support layer (12), wherein the matrix boundary layer (32) comprises a part of the tissue layer (14) which is impregnated with resin of the carrier layer (12), wherein the matrix boundary layer (32) extends continuously around a circumferential edge (34) of the tissue layer (14), and wherein the lower wall (24) comprises a continuous circumferential shoulder (26) adjacent to the matrix boundary layer (32) and includes at least one support section (28) spanning the continuous circumferential shoulder (26); a cushion (16) that lies in the inlet (20) above the tissue layer (14); and a covering material (18) that conceals the padding (16) and the fabric layer (14) and seals the receptacle (20).

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