Trim panel assembly having an integrated door bumper and method of manufacture

Abstract

In at least certain embodiments, the present invention relates to a trim panel assembly and a method of making the same. The trim panel assembly comprises a housing having a perimeter portion defining an opening. The housing comprises a housing panel and a housing skin covering at least a portion of the housing panel. The trim panel assembly further comprises a door moveable between a first position wherein the door closes the opening to a second position wherein the door provides access to the opening. The door comprises a door panel and a door skin covering at least a portion of the door panel. The trim panel assembly further comprises a bumper disposed between the housing and the door. The bumper and at least one of the skins are made during the same injection molding step.

1 . A method for making trim panel assembly, said method comprising: 
 providing a housing comprising a housing panel having a perimeter portion defining an opening, and a housing skin covering at least a portion of the housing panel;    providing a door connectable with the housing which is moveable between a first position wherein the door closes the opening to a second position wherein the door provides access to the opening, the door comprising a door panel and a door skin covering at least a portion of the door panel; and    providing a bumper disposed between the housing and the door, where the bumper and at least one of the skins are made during the same injection molding step.    
     
     
         2 . The panel assembly of  claim 1  wherein the bumper is located on the door or the housing perimeter portion.  
     
     
         3 . The trim panel assembly of  claim 1  wherein an extension portion extends between and connects the bumper and the at least one skin, the extension portion and the bumper being made of the same material.  
     
     
         4 . The trim panel assembly of  claim 3  wherein the extension portion extends through the door panel.  
     
     
         5 . The trim panel assembly of  claim 3  wherein the extension portion extends around an edge of the door panel.  
     
     
         6 . The trim panel assembly of  claim 2  wherein an extension portion extends between and connects the bumper and the housing skin.  
     
     
         7 . The instrument panel of  claim 6  wherein the extension portion has at least a portion extending through the housing panel.  
     
     
         8 . The trim panel assembly of  claim 6  wherein the extension portion is on the housing perimeter portion.  
     
     
         9 . The trim panel assembly of  claim 3  wherein the extension portion and the at least one of the skins are made of a first material, at least one of the door panel and the housing panel being made of a second material more rigid than the first material.  
     
     
         10 . The trim panel assembly of  claim 1  wherein the bumper comprises a first portion on the door and a second portion facing the first portion and being located on the housing.  
     
     
         11 . The trim panel assembly of  claim 9  wherein the first material is an elastomer and the second material is rigid polymeric material.  
     
     
         12 . The trim panel assembly of  claim 1  wherein the door is a glove box door and the housing is a glove box compartment.  
     
     
         13 . The trim panel of  claim 1  wherein the bumper and the at least one skin are made of the same material.  
     
     
         14 . The method of  claim 1  further comprising providing an extension portion extending between and connecting the bumper and at least one skin with the bumper, the at least one skin and the extension portion being formed together within the same mold and being made of a first material which is less rigid than the material used to form at least one of the panels.  
     
     
         15 . A method for making trim panel assembly comprising a housing panel having a perimeter portion defining an opening and a housing skin covering at least a portion of the housing panel, and a door connectable with the housing which is moveable between a first portion wherein the door closes the opening to a second position wherein the door provides access to the opening, said method comprising: 
 injecting a first plastic material into an injection mold to form one of the housing and the door;    injecting a second, less rigid, plastic material into the mold to form (i) one of the housing skin and the door skin, and (ii) a bumper disposed between the housing and the door, wherein the bumper and the one skin are made during the same injection molding step.    
     
     
         16 . A method for making trim panel assembly, said method comprising: 
 forming a housing comprising a housing panel having a perimeter portion defining an opening;    forming a housing skin covering at least a portion of the housing panel;    forming a door panel connectable with the housing which is moveable between a first position wherein the door closes the opening to a second position wherein the door panel provides access to the opening;    forming a door skin covering at least a portion of the door panel; and    forming a bumper disposed between the housing and the door panel, wherein the bumper and at least one of the skins are made during the same injection molding step.    
     
     
         17 . The method of  claim 16 , wherein the forming a housing step comprises injecting a first plastic material into an injection mold, the forming a housing skin step comprises injecting a second plastic material into the injection mold; and 
 the forming a bumper step comprises injecting the second plastic material into the injection mold.    
     
     
         18 . The method of  claim 16 , wherein the forming a door panel step comprises injecting a first plastic material into an injection mold, the forming a door skin step comprises injecting a second plastic material into the injection mold; and 
 the forming a bumper step comprises injecting the second plastic material into the injection mold.