Interior vehicle trim panel having dual density spray elastomer and method for making the same
The present invention provides a vehicle interior trim panel. The panel may be made by providing a spray mold having a mold surface having a cavity having a portion having a height to depth (H/D) ratio of less than 1.0. Polyurethane material can be sprayed proximate the surface of the tool to form a polyurethane skin layer. Expandable polyurethane material can be sprayed onto the skin layer to form a resilient layer. The skin layer and the resilient layer can be removed from the tool and positioning in a mold in a spaced apart relationship from a substrate, with a foam material being introduced between the substrate and the resilient layer to form a foam layer therebetween.
1 . A method for making a vehicle interior trim panel, said method comprising:
providing a spray mold having a mold surface having a cavity having at least a portion having a height to depth (H/D) ratio of less than 1.0,
spraying polyurethane material proximate the surface of the tool to form a polyurethane skin layer;
spraying expandable polyurethane material onto the skin layer to form a resilient layer;
removing the skin layer and the resilient layer from the tool and positioning the skin layer and the resilient layer in a mold in a spaced apart relationship from a substrate; and
introducing a foam material between the substrate and the resilient layer to form a foam layer between the substrate and the resilient layer.
2 . The method of claim 1 wherein the skin layer has a predetermined first color and the resilient layer has a predetermined second color substantially similar to the first color.
3 . The method of claim 2 wherein the second color is the same as the first color.
4 . The method of claim 1 wherein the cavity has a portion having a height to depth (H/D) ratio of 0.1 to 0.5.
5 . The method of claim 4 wherein the resilient layer has a first portion extended generally in a first direction, a second portion extending generally in a second direction, generally transverse from the first direction, and a nose portion extending between and connecting the first and second portions, the nose portion having a height to depth ratio of less than 1.0.
6 . The method of the claim 1 wherein the nose portion has a substantial portion having a height to depth ratio of 0.1 to 0.5.
7 . The method of claim 6 wherein the resilient layer has a density of 0.1 to 0.75 g/cm 3 .
8 . The method of claim 7 wherein the skin layer has a density of 0.85 to 1.2 g/cm 3 .
9 . The method of claim 8 wherein the first and second portions of the resilient layer have a thickness of 0.1 to 6 mm.
10 . A vehicle interior trim component for use with a motor vehicle, the trim component comprising:
a sprayed polyurethane skin layer;
a sprayed expanded polyurethane resilient layer secured to the skin layer, the resilient layer having a first portion extending in a first direction, a second portion extending in a second direction, generally transverse to the first direction, and a nose portion extended between and connecting the first and second portions, the nose portion having at least a portion having a height to depth ratio of less than 1.0; and
a rigid substrate secured to the resilient layer.
11 . The vehicle interior trim component of claim 10 wherein the skin layer has a predetermined first color and the resilient layer has a predetermined second color substantially similar to the first color.
12 . The vehicle interior trim component of claim 11 wherein the second color is the same as the first color.
13 . The vehicle interior trim component of claim 10 wherein the nose portion has a height to depth (H/D) ratio of 0.1 to 0.5.
14 . The vehicle interior trim component of claim 10 wherein the nose portion has at least a substantial portion having a height to depth ratio of 0.1 to 0.5.
15 . The vehicle interior trim component of claim 10 wherein the resilient layer has a density of 0.1 to 0.75 g/cm 3 .
16 . The vehicle interior trim component of claim 15 wherein the skin layer has a density of 0.85 to 1.2 g/cm 3 .
17 . The vehicle interior trim component of claim 16 wherein the first and second portions of the resilient layer have a thickness of 0.1 to 6 mm.
18 . A method for making a vehicle interior trim panel, said method comprising:
providing a spray mold having a mold surface having a cavity having a portion having a height to depth (H/D) ratio of less than 1.0,
spraying polyurethane material proximate the surface of the tool to form a polyurethane skin layer;
spraying expandable polyurethane material onto the skin layer to form a resilient layer, the resilient layer having a first portion extended generally in a first direction, a second portion extending generally in a second direction, generally transverse from the first direction, and a nose portion extending between and connecting the first and second portions, the nose portion having a height to depth ratio of less than 1.0, the expanded polyurethane material being sprayed longer in the vicinity of the cavity than in the other potions of the mold surface;
removing the skin layer and the resilient layer from the tool and positioning the skin layer and the resilient layer in a mold in a spaced apart relationship from a substrate; and
introducing a foam material between the substrate and the resilient layer to form a foam layer between the substrate and the resilient layer.
19 . The method of claim 18 wherein the skin layer has a predetermined first color and the resilient layer has a predetermined second color substantially similar to the first color.
20 . The method of claim 19 wherein the resilient layer has a density of 0.1 to 0.75 g/cm 3 .