Method for manufacturing a vehicle interior component

Abstract

A process for manufacturing a vehicle interior component may involve heating a polymer material to a molten state to produce a molten polymer. The molten polymer can be extruded to form a plurality of molten polymer filaments. A fastening assembly 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 assembly is attached.

Description

Cross-reference to related applications

[0001] This application claims the benefits of Danish Patent Application No. PA202370026, filed on January 19, 2023, which in turn claims the benefits of provisional US Application No. 63 / 356,249, filed on June 28, 2022, the disclosures of which are hereby incorporated by reference in their entirety. Technical field

[0002] The present disclosure relates to a method and a device for manufacturing an interior vehicle component. Brief description of the drawings Fig. 1 shows a schematic representation of a system and method according to embodiments described herein; Fig. 2 shows a schematic representation of an embodiment of a part of the method shown in Fig. 1; Fig. 3 shows a schematic representation of a fastening arrangement which can be used with the Fig. 2 can be used; Fig. 4 shows a schematic representation of an embodiment of a part of the Fig. 1 shown procedure; Fig. 5 shows a secondary extrusion head that may be used as part of a system and method according to embodiments described herein; Fig. 6 shows a consolidated filament structure with a fastening assembly attached thereto in accordance with embodiments described herein; Fig. Figure 7 shows a schematic representation of an embodiment of a part of the Fig. 1 shown method; and

[0003] The Fig. 8A-8C show a schematic representation of steps involved in the Fig. 7 shown embodiment can be carried out. Detailed description

[0004] Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the various described embodiments. However, it will be apparent to one skilled in the art that the various described embodiments may be practiced without these specific details. In other instances, well-known methods, procedures, components, circuits, and networks have not been described in detail in order not to unnecessarily obscure aspects of the embodiments.

[0005] It should be understood that the disclosed embodiments are merely exemplary, and that various and alternative forms are possible. The figures are not necessarily to scale; some features may be exaggerated or reduced to show details of particular components. Therefore, the specific structural and functional details disclosed herein are not to be construed as limiting, but merely as a representative basis for enabling one skilled in the art to utilize various embodiments in accordance with the disclosure.

[0006] “One or more” includes a function performed by one element, a function performed by more than one element, for example, in a distributed form, multiple functions performed by one element, multiple functions performed by multiple elements, or any combination of the above.

[0007] It should also be understood that although the terms "first," "second," etc., are used herein in some instances to describe various elements, those elements should not be limited by these terms. These terms are used only to distinguish one element from another. For example, a first contact could be referred to as a second contact, and likewise, a second contact could be referred to as a first contact, without departing from the scope of the various described embodiments. The first contact and the second contact are both contacts, but they are not the same contact.

[0008] The terminology used in the description of the various embodiments is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various embodiments and the appended claims, the singular forms "a," "an," and "the" are intended to include the plural forms unless the context clearly indicates otherwise. It is further understood that the terms "includes," "including," "comprises," or "comprising," when used in this description, specify the presence of certain features, integers, steps, acts, elements, or components, but do not preclude the presence or addition of one or more other features, integers, steps, acts, elements, components, or groups thereof.

[0009] The term "if" can be understood as "when" or "at" or "in response to noting" or "in response to detecting," depending on the context. Similarly, the expression "when it is determined" or "when [a particular condition or event] is detected" can be understood as "at the determination" or "in response to the determination" or "upon detecting [the particular condition or event]" or "in response to detecting [the particular condition or event]," depending on the context.

[0010] Referring to Fig. 1, a schematic representation of a system 10 is shown that can be used with a method 11 according to the embodiments described herein. A container 12 contains solid granules of a polymeric material 14 to be extruded. In this embodiment, the material 14 is linear low-density polyethylene (LLDPE), although other types of polymers can be used in the methods described herein if desirable and effective to produce the finished product. The material 14 is fed from the container 12 to an extruder 16. The extruder 16 melts and transports the material 14 to a die assembly 18 containing a die 20. The extruder 16 can, for example, be a conventional extruder including a barrel that receives a rotatable screw.The rotation of the screw forces the material 14 to move through the cylinder and, due to the friction generated during the rotation of the screw, contributes to heating the material. Heating elements can be arranged on the cylinder to heat the polymeric material 14 inside the cylinder.

[0011] The material 14 exits the extruder 16 at location 22 under pressure and in a molten state. Unless otherwise specified, the term "molten" as used herein means that the material is at least partially molten. It does not mean that the material is necessarily in a completely liquid state; rather, it means that the material is not completely solid and can still flow through the elements of the system 10. For example, the molten material may still flow through the die plate 20, but it may be very viscous and begin to solidify. Once the solid granules of polymer material 14 in the extruder 16 are molten, the material begins to cool as it is no longer moved by the extruder screw and moves away from any heating devices.At different points in the process 11 the material may have a higher or lower viscosity, but if it is still partially molten and can flow - even slowly - the term "molten" is used here.

[0012] The nozzle plate 20 extrudes the material 14 into filaments 24. More specifically, the nozzle plate 20 has several holes 21 arranged through it - see e.g. Fig. 2 - through which the molten material 14 passes. A single filament 24 is extruded from each hole in the nozzle plate. The filaments 24 fall downward from the nozzle plate 20 under system pressure and gravity into a hopper 26. The hopper 26 helps consolidate or group the filaments 24 into a more compact arrangement in which the filaments 24 bend or loop, and each filament 24 touches and is connected 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.Individual severed filaments 24 enter the hopper inlet 28, the filaments 24 then bend or entangle and come into contact with each other as they accumulate and slide down the hopper 26 to the hopper outlet 30, and the consolidated filament structure 32 exits the hopper outlet 30 and enters a water tank 34. When the filaments 24 reach the hopper 26, those filaments that are near the outer portion of the hopper 26—approximately 2 to 3 rows—slide down an inclined surface of the hopper 26, forming a skin on the consolidated filament structure 32.

[0013] The water tank 34 contains water 36 and receives the consolidated filament structure 32 from the hopper 26. The water 36 serves 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. As such, the water 36 provides a degree of resistance that causes the additional bending and entanglement of the filaments 24 to further build the consolidated filament structure 32. Second, the water 36 externally cools the polymer filaments 24 to solidify them. The temperature of the water 36 can be much lower than the temperature of the filaments 24 as they exit the nozzle plate 20; for example, it can be the same temperature as the ambient temperature of the tank 34.Although liquid water 36 is used in this embodiment, other types of fluids may be used in other embodiments.

[0014] The water tank 34 contains various rollers and conveyors that help move the consolidated filament structure 32 through and out of the water 36. A tractor conveyor 38 is submerged in the water 36 and engages the opposite lateral sides of the consolidated filament structure 32 to move it away from the hopper 26 at approximately the same speed as the consolidated filament structure 32 exits the hopper 26. The gap between the opposite parts of the tractor conveyor 38 is slightly narrower than the width of the consolidated filament structure 32 to allow the tractor conveyor 38 to better grip the consolidated filament structure 32. As previously mentioned, Fig. 1 is a schematic diagram simplified for illustrative purposes. For example, a conveyor, such as the tractor conveyor 38, may be arranged toward the front and rear of the system 10, as shown in Fig. 1, and instead of the left and right sides as shown.

[0015] Another roller 40 helps keep the consolidated filament structure 32 submerged and guides it through the water 36 to a conveyor belt 42 and a vibrating table 44 positioned outside the water tank 34. The vibrating table 44 vibrates the consolidated filament structure 32 while it is on the conveyor belt 42 to remove at least some of the water 36. Pressurized air can also be blown onto the consolidated filament structure 32, which can also be squeezed to remove more water 36. Finally, the consolidated filament structure 32 can be cut to the desired size and shape. As described above, the consolidated filament structure 32 forms a fabric that can be used, for example, as a cushion blank for a piece of a vehicle interior component.In some cases, the consolidated filament structure 32 may have a rectangular cross-section that is later cut or shaped to a desired contour for the intended use.

[0016] Fig. Figure 2 shows a portion of a system, such as system 10, that performs an embodiment of the method described herein. More specifically, Fig. 2 a nozzle plate 46 having a plurality of holes arranged therethrough, which is used to extrude a molten polymer into a plurality of molten polymer filaments 48, of which in Fig. 2 For the sake of clarity, only some are labeled. Similar to the Fig. 1, the molten polymer filaments 48 fall downward from the nozzle plate 46 toward a funnel assembly 50. After passing through the funnel assembly 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 already described in connection with Fig. As described in Figure 1, the fluid bath serves, among other things, to cool the molten polymer. Fig. Figure 2 also shows the step of introducing a fastener assembly 56 into the molten polymer. In this step, the fastener assembly 56 is inserted into or combined with the molten polymer. In this embodiment, the fastener assembly 56 is introduced into the molten polymer after the molten polymer filaments 48 have been formed. As explained in more detail below, in other embodiments, a fastener assembly, such as the fastener assembly 56, may be introduced into the molten polymer as it is extruded through a die plate, i.e., through the same die plate in which the molten polymer filaments 48 are formed.

[0017] As in Fig. 2, the fastening arrangement 56 includes a thread portion 58 configured as an elongated member. The fastening arrangement 56 may comprise a plastic bead, a fabric material, e.g., Duon, or a cord, rope, or similar structure. When this type of fastening arrangement is used, it may, for example, provide a fastening for rings, clips, etc., attached to a trim cover or other material to be positioned over the resulting product, such as a consolidated filament structure. As described in connection with Fig. 3, the fastening arrangement 56 may comprise a plurality of individual fastening elements. The thread portion 58 may have a defined length, in particular a defined length long enough to cover the length of a resulting product, such as the one shown in Fig. 1 shown consolidated filament structure 32. In the Fig. In the embodiment shown in Figure 2, the fastening assembly 56, in particular the thread 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 rotating in the direction indicated by the directional arrow 62.

[0018] As described above, a fastening assembly, such as the fastening assembly 56, may comprise a plurality of individual fastening elements, as shown in Fig. 3 schematically shown. In the Fig. 3, a fastening assembly 64 includes a thread portion 66 that forms an elongated element of the fastening assembly 64. The Fig. The fastener assembly 64 shown in Figure 3 is a segment of a potentially much longer structure. In addition to the thread portion 66, the fastener assembly 64 also includes a plurality of individual fasteners 68, which may be, for example, Christmas tree fasteners, clips, pins, etc. Because the fasteners 68 are attached to the thread portion 66, which is continuously fed into 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 speed of insertion of the fastener assembly 64 into the molten polymer.

[0019] The fastener elements 68 are also introduced and inserted into the molten polymer at predetermined locations, which again can be defined by the distance between the fastener elements 68 and the speed at which the fastener assembly 64 is introduced into the molten polymer. The locations of the fastener elements 68 relative to the molten polymer filaments 48 can also be determined by where the fastener elements 68 are positioned when inserted into the molten polymer. In the Fig. For example, in the embodiment illustrated in Figure 2, the fastening assembly 56 is inserted very close to an edge of the molten polymer filaments 48. This may result in a finished product in which the fastening assembly 56 is mounted very close to a surface, making it easily accessible for attachment to other products.

[0020] Fig. 4 also shows a portion of a system, such as system 10, that performs an embodiment of the method described herein. More specifically, Fig. 4 a nozzle plate 70 having a plurality of holes therethrough is arranged, which is used to extrude a molten polymer into a plurality of molten polymer filaments 72, of which in Fig. 4 For clarity, only some are labeled. Similar to the Fig. 1, the molten polymer filaments 72 fall downward from the nozzle plate 70 and are received by a hopper assembly 74. After being introduced into and passing through the hopper assembly 74, the molten polymer filaments 72 enter a fluid tank 76, which in this embodiment contains water 78. A fastening assembly 80 contains a thread portion 82 which corresponds to the Fig. 2 and the thread part 58 shown in Fig. 3 may be similar to the thread part 66 shown. In the Fig. In the embodiment shown in Figure 4, the fastener assembly 80 is introduced into the molten polymer through a larger hole 84 in the die plate 70, which may be referred to as a "co-extrusion" technique. The thread portion 82 may be continuously fed through the hole 84 while the molten polymer is extruded into the molten polymer filaments 72.

[0021] Fig. Figure 1 shows a secondary extrusion head 85 through which the fastening assembly 80 can be inserted under the nozzle plate 20, in phantom view. A bottom view of the secondary extrusion head 85 is shown in Fig. 5, which is opposite the nozzle plate 20. As in Fig. 5, a fastener assembly, such as the fastener assembly 80, may be inserted through the secondary extrusion head 85 and in particular through an opening 87.

[0022] In applications where the mounting arrangement does not include individual fasteners - such as those in Fig. 3, the thread portion 82 may be inserted through one of the standard holes in the nozzle plate 70. Alternatively, a special inlet tube could be inserted through the nozzle plate 70 to accommodate a mounting arrangement with individual fasteners that are larger than the standard holes in the nozzle plate. Fig. 6 shows a portion of a consolidated filament structure 86 to which a fastening assembly 88 is attached. The fastening assembly 88 includes a thread portion 90 that is attached to the consolidated filament structure 86. More specifically, the fastening assembly 88 is attached to the filaments 92 - of which Fig. 6 for the sake of clarity only some are labelled - by placing it in contact with them while they are still in a molten state, so that when the filaments 92 cool down a secure connection is formed.

[0023] In Fig. 7 is a part of a system, like system 10. More precisely, Fig. 7, a nozzle plate 94 having a plurality of holes therethrough is arranged, which is used for extruding a molten polymer into a plurality of molten polymer filaments 96. For the sake of clarity, Fig. 7, only some of the polymer filaments 96 are labeled. The molten polymer filaments 96 fall downward from the nozzle plate 94, where they are introduced into a funnel assembly 98. After leaving the funnel assembly 98, the polymer filaments 96 enter a fluid tank 100, which in this embodiment contains water 102. In the Fig. 7, a fastening assembly can be introduced into the molten polymer filaments 96 through the funnel assembly 98. The isolated detail 7 in Fig. 7 is in Fig. 8A is shown enlarged. A schematic representation of the process of inserting a fastener assembly into the molten polymer filaments 96 through the funnel assembly 98 is shown in the Fig. 8B and Fig. 8C shown.

[0024] In Fig. 8A, a portion 104 of the funnel assembly 98 is shown. As in Fig. 8A, the portion 104 of the funnel assembly 98 prevents a fastener assembly 106 from being inserted into the molten polymer filaments 96. In the Fig. 6 and Fig. 7, the portion 104 of the funnel assembly 98 is movable to allow the attachment assembly 106 to be combined with the molten polymer filaments 96. This is shown in Fig. 8B, where the portion 104 of the funnel assembly 98 has been moved to the left, as indicated by the directional arrow 108. This allows the mounting assembly 106 to move downward, as indicated by the directional arrow 110. In the Fig. 8B and Fig. 8C, the molten polymer filaments 96 have been removed for clarity. Once the fastener assembly 106 is inserted into the molten polymer filaments 96, the portion 104 of the funnel assembly 98 is returned to its original position, as indicated by directional arrow 112. This embodiment allows individual fasteners to be placed in contact with the molten polymer filaments 96 at a predetermined frequency and at predetermined locations.

[0025] While exemplary embodiments are described above, these embodiments are not intended to describe all possible forms according to the disclosure. In this regard, the words used in the description are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosure. Furthermore, the features of the various embodiments may be combined to form further embodiments according to the disclosure. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] US 63 / 356,249

[0001]

Claims

[1] A method for manufacturing a vehicle interior component, comprising: Heating a polymer material to a molten state so that it becomes a molten polymer; Introducing the molten polymer into a nozzle plate having a plurality of through holes so that the molten polymer moves through the holes and forming a plurality of molten polymer filaments; introducing a fastening assembly into the molten polymer; and Cooling the molten polymer after it leaves the nozzle plate so that a consolidated filament structure is formed and the attachment assembly is attached to the consolidated filament structure. [2] The method of claim 1, wherein the fastener assembly is introduced into the molten polymer after the molten polymer has been introduced into the nozzle plate. [3] The method of claim 1, wherein the fastener assembly is introduced into the molten polymer through the nozzle plate. [4] The method according to any one of the preceding claims, wherein the fastening arrangement comprises a thread portion having a length and the thread portion is continuously introduced into the molten polymer over at least a portion of the length. [5] The method according to any one of the preceding claims, wherein the fastening arrangement comprises a plurality of individual fastening elements and the fastening elements are introduced into the molten polymer at a predetermined frequency. [6] The method of claim 1 or 2, wherein cooling the molten polymer includes introducing the molten polymer into a fluid bath, the method further comprising receiving the molten polymer with a hopper assembly before introducing the molten polymer into the fluid bath, and wherein the fastener assembly comprises a plurality of individual fasteners and the fasteners are introduced into the molten polymer through the hopper assembly. [7] A vehicle interior component formed by the method of any preceding claim. [8] A method for manufacturing a vehicle interior component, comprising: Heating a polymer material to a molten state to produce a molten polymer; Extruding the molten polymer to form a plurality of molten polymer filaments; Inserting a fastener assembly into the molten polymer; and cooling the molten polymer in a fluid bath to create a consolidated filament structure to which the fastener assembly is attached. [9] The method of claim 8, wherein the fastening assembly includes an elongate member, and inserting the fastening assembly into the molten polymer comprises continuously feeding the elongate member into the molten polymer over at least a portion of a length of the elongate member. [10] The method of claim 8 or 9, wherein the elongate member includes a plurality of individual fasteners. [11] The method of claim 8 or 9, wherein the fastening assembly comprises a plurality of individual fastening elements and the fastening elements are inserted into the molten polymer at predetermined locations in the molten polymer. [12] The method of claim 11, further comprising introducing the molten polymer into a hopper assembly prior to cooling the molten polymer in the fluid bath, wherein the fasteners are inserted through the hopper assembly into the molten polymer. [13] The method of any preceding claim, wherein the fastener assembly is inserted into the molten polymer after the molten polymer has been extruded to form the molten polymer filaments. [14] The method of any one of claims 8-11, wherein the fastener assembly is inserted into the molten polymer while the molten polymer is extruded to form the molten polymer filaments. [15] The method of any one of claims 8-11 or 14, wherein extruding the molten polymer includes introducing the molten polymer into one extruder and inserting the fastener assembly into the molten polymer includes inserting the fastener assembly through another extruder. [16] A cushion blank for a vehicle interior component formed by the method of any one of claims 8-15. [17] The method for manufacturing a vehicle interior component, comprising: Heating a polymer material to produce a molten polymer; forming a plurality of molten polymer filaments from the molten polymer; Combining a fastener assembly with the molten polymer; and cooling the molten polymer in a fluid bath to create a consolidated filament structure to which the fastener assembly is attached. [18] The method of claim 17, wherein the fastening assembly is combined with the molten polymer after the molten polymer filaments have been formed. [19] The method of claim 17, wherein the fastening assembly is combined with the molten polymer while the molten polymer filaments are formed. [20] The method of any one of claims 17-19, wherein the fastening assembly includes an elongate member and combining the fastening assembly with the molten polymer comprises continuously feeding the elongate member into the molten polymer over at least a portion of a length of the elongate member.

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