Methods for making inflatable interior panel arrangements for motor vehicles

Patent metadata

Field	Value
Publication number	US-9975279-B2
Application number	US-201514920215-A
Country	US
Kind code	B2
Filing date	Oct 22, 2015
Priority date	Oct 22, 2015
Publication date	May 22, 2018
Grant date	May 22, 2018

Abstract

Methods for making inflatable interior panel arrangements for motor vehicles are provided. In one example, a method includes introducing a first molding material into a molding tool that has tooling surfaces. A second molding material is introduced into the molding tool. The molding tool is advanced to a closed configuration such that the tooling surfaces define a substantially enclosed cavity in the molding tool. An inflatable interior panel is formed including rotating the molding tool to cover the tooling surfaces of the substantially enclosed cavity with the first molding material and/or the second molding material. The inflatable interior panel includes an inflatable bladder section and an outer panel section that is integrally coupled to the inflatable bladder section and that has a panel portion stiffness greater than a bladder portion stiffness of the inflatable bladder section.

First claim

What is claimed is:

1. A method for making an inflatable interior panel arrangement for a motor vehicle, the method comprising the steps of:
introducing a first molding material into a molding tool that has tooling surfaces;
introducing a second molding material into the molding tool;
advancing the molding tool to a closed configuration such that the tooling surfaces define a substantially enclosed cavity in the molding tool; and
forming an inflatable interior panel comprising rotating the molding tool to cover the tooling surfaces of the substantially enclosed cavity with the first molding material and/or the second molding material, wherein the inflatable interior panel comprises an inflatable bladder section and an outer panel section that is integrally coupled to the inflatable bladder section and that has a panel portion stiffness greater than a bladder portion stiffness of the inflatable bladder section.

2. The method of claim 1 , wherein during forming the inflatable interior panel the first molding material and the second molding material are, independently, in a liquid phase and/or a molten condition before and/or during rotating the molding tool to facilitate covering the tooling surfaces of the substantially enclosed cavity, and wherein forming the inflatable interior panel further comprises:
solidifying the first molding material to form a first solidified molded material; and
solidifying the second molding material to form a second solidified molded material, wherein the first solidified molded material has a higher flexural modulus than the second solidified molded material.

3. The method of claim 2 , wherein solidifying the first molding material comprises forming the first solidified molded material having a flexural modulus of from 800 to 1300 MPa at 23° C.

4. The method of claim 2 , wherein solidifying the second molding material comprises forming the second solidified molded material having a flexural modulus of from 1 to 500 MPa at 23° C.

5. The method of claim 2 , wherein solidifying the second molding material comprises forming the second solidified molded material having an ultimate elongation of from 25% to 500% at 23° C.

6. The method of claim 2 , wherein forming the inflatable interior panel comprises forming the outer panel section comprising the first solidified molded.

7. The method of claim 2 , wherein forming the inflatable interior panel comprises forming the inflatable bladder section comprising the second solidified molded.

8. The method of claim 1 , wherein introducing the first molding material comprises depositing the first molding material in a liquid phase overlying the tooling surfaces associated with a first portion of the molding tool.

9. The method of claim 8 , wherein introducing the first molding material comprises depositing the first molding material that comprises a curable polymeric precursor and a hardener, and wherein forming the inflatable interior panel comprises curing the curable polymeric precursor with the hardener prior to introducing the second molding material and rotating the molding tool.

10. The method of claim 8 , wherein introducing the first molding material comprises depositing the first molding material overlying the tooling surfaces associated with the first portion of the molding tool using a spray process.

11. The method of claim 1 , wherein introducing the second molding material comprises depositing the second molding material overlying the tooling surfaces associated with a first portion of the molding tool, and wherein forming the inflatable interior panel comprises rotating the molding tool to move at least a portion of the second molding material over the tooling surfaces associated with a second portion of the molding tool.

12. The method of claim 11 , wherein introducing the second molding material comprises depositing the second molding material in a powder form overlying the tooling surfaces associated with the first portion of the molding tool.

13. The method of claim 12 , wherein forming the inflatable interior panel comprises:
applying heat to the second molding material in the powder form during rotation of the molding tool to melt the second molding material and form a molten second molding material overlying the tooling surfaces associated with the second portion of the molding tool; and
cooling the molten second molding material to form a second solidified molded material.

14. The method of claim 1 , further comprising:
advancing the molding tool to an open configuration open the substantially enclosed cavity and remove the inflatable interior panel from the molding tool;
forming an opening in the inflatable bladder section; and
operatively coupling an inflator to the inflatable bladder section about opening.

Assignees

• Faurecia Interior Systems Inc

Inventors

• Salandre Maxime

Classifications

• B29L2031/3055

  Cars · CPC title

• B29K2063/00

  Use of {EP, i.e.} epoxy resins {or derivatives thereof}, as moulding material · CPC title

• B29C41/22

  Making multilayered or multicoloured articles · CPC title

• B29L2031/3038

  Air bag covers · CPC title

• B29L2009/00

  Layered products · CPC title