Open core crash pad and process for manufacturing thereof

Patent metadata

Field	Value
Publication number	US-9623639-B2
Application number	US-201514930263-A
Country	US
Kind code	B2
Filing date	Nov 2, 2015
Priority date	Dec 9, 2014
Publication date	Apr 18, 2017
Grant date	Apr 18, 2017

Abstract

An open core crash pad includes a core and a skin abutting the core to include a forming space therebetween. A foaming layer is foam-formed by injecting a foam liquid into the forming space. A foam tape prevents an overflow of the foam liquid. The skin includes a body portion and a distal end which extends from the body portion in parallel with the core. The core comprises a protrusion protruding toward the skin and formed at which the core and the distal end contact.

First claim

What is claimed is:

1. An open core crash pad comprising:
a core;
a skin abutting the core to include a forming space therebetween;
a foaming layer foam-formed by injecting a foam liquid into the forming space; and
a foam tape for preventing an overflow of the foam liquid,
wherein the skin comprises: a body portion; and a distal end extending from the body portion in parallel with the core,
wherein the core comprises a protrusion protruding toward the skin and formed at which the core and the distal end contact,
wherein the distal end comprises a recessed section which is recessed from an outer surface of the skin at which the distal end contacts the protrusion,
wherein the distal end is attached with the foam tape, and
wherein the distal end and the foam tape are configured to be removed together from the open core crash pad.

2. The open core crash pad of claim 1 , wherein the protrusion and the foam tape are attached to each other.

3. The open core crash pad of claim 1 , wherein the protrusion comprises a head which is inclined and has a sharp end.

4. The open core crash pad of claim 1 , wherein the skin is a polyvinyl chloride (PVC) powder slush.

5. A method of manufacturing an open core crash pad comprising:
inserting a core into an upper mold and inserting a skin into a lower mold;
attaching a foam tape to the core or the skin;
injecting a foam liquid into a forming space of the skin; and
manufacturing a foaming layer by pressing the upper mold and the lower mold,
wherein the skin comprises: a body portion; and a distal end extending from the body portion in parallel with the core,
wherein the core comprises a protrusion protruding toward the skin and formed at which the core and the distal end contact, and
wherein the distal end comprises a recessed section recessed from an outer surface of the skin at which the distal end contacts the protrusion, and the distal end is configured to be removed together with the foam tape.

6. The method of claim 5 , wherein the foam tape is closely attached to the protrusion when the upper mold and the lower mold are pressed.

7. The method of claim 5 , wherein the protrusion comprises a head which is inclined and has a sharp end.

Assignees

• Hyundai Motor Co Ltd
• Kia Motors Corp

Inventors

• Kong Byung Seok

Classifications

• B29C44/14

  the preformed part being a lining {(B29C44/1209 takes precedence)} · CPC title

• B29L2031/3005

  Body finishings · CPC title

• B32B1/00

  Layered products having a non-planar shape · CPC title

• B32B3/30

  characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)} · CPC title

• B32B2571/00

  Protective equipment · CPC title