Armrest having armrest bun and method of manufacture

Abstract

An armrest bun. The armrest bun inserts within an armrest to provide cushioning. The armrest bun includes a support substrate and a poured foam layer. The bun inserting within a cavity of the armrest. The foam layer shaped to match the armrest cavity to limit dead-spots. The bun can be manufactured by position a support substrate in a pouring tool. Foam is poured into a cavity of the pouring tool. The poured foam solidifies to bond to the support substrate. The bun can then be inserted into the armrest.

1 . A method of manufacturing an armrest bun, the method comprising: 
 configuring a pour tool to include a cavity and a fixture, the fixture configured to receive a support substrate;    positioning the support substrate in the fixture such that a portion of the support substrate is in communication with the cavity; and    pouring a foam material into the cavity, the foam material sufficient to bond to the portion of the support substrate in communication with the cavity.    
     
     
         2 . The method of  claim 1  further comprising defining the cavity to include a curvature, the curvature matching a curvature in an armrest cavity, the poured foam shaped by the cavity curvature so that the foam forms to match the armrest cavity curvature.  
     
     
         3 . The method of  claim 1  further comprising defining the cavity to include a taper, the taper matching a taper in an armrest cavity, the poured foam shaped by the cavity taper so that the foam forms to match the armrest cavity taper.  
     
     
         4 . The method of  claim 1  wherein the support substrate includes an elongated prong, and wherein the method further comprise positioning the support substrate so that the elongated prong extends into the cavity, the poured foam chemically bonding to the elongated prong.  
     
     
         5 . The method of  claim 4  wherein the elongated prong includes an aperture, and the method further comprises positioning the support substrate so that the aperture is positioned within the cavity, at least a portion of the poured foam pouring through the aperture and chemically bonding thereto.  
     
     
         6 . The method of  claim 1  wherein the support substrate includes a funnel, the funnel extending from one side of the substrate through to an opposite side of the support substrate, and wherein the method further comprising positioning the support substrate so that the poured foam pours through the funnel to reach the cavity.  
     
     
         7 . A method of manufacturing an armrest, the method comprising: 
 pouring a foam into a shape suitable for use in the armrest;    attaching the foam to a door used to support the armrest; and    attaching an armrest skin over the attached foam and to the door to form the armrest.    
     
     
         8 . The method of  claim 7  further comprising pouring the foam into a cavity having a shape corresponding with a curvature of the armrest skin such that the poured foam matches the curvature of the armrest skin.  
     
     
         9 . A method of manufacturing an armrest, the method comprising: 
 pouring a foam material to form a foam layer;    adhering the foam layer to a substrate, the foam layer and substrate defining an armrest bun; and    inserting the armrest bun into a cavity of the armrest.    
     
     
         10 . The method of  claim 9  wherein a portion of the cavity has a curvature, and the method further comprises pouring the foam material to include a corresponding curvature such that the inserted armrest bun snuggly fits to the curvature of the cavity to limit dead-spots.  
     
     
         11 . The method of  claim 9  wherein a portion of the cavity has a taper, and the method further comprises pouring the foam material to include a corresponding taper such that the inserted armrest bun snuggly fits to the taper of the first cavity to limit dead-spots.  
     
     
         12 . The method of  claim 9  wherein the armrest includes a shoulder on an opening side of the cavity, and wherein the method further comprising positioning a channel on the substrate such that the channel mates with the shoulder.  
     
     
         13 . The method of  claim 9  wherein the armrest includes a flexible skin that includes a lip extending over an opening side of the cavity, and wherein the method further comprises positioning a ridge on the substrate such that the lip flexes over the substrate to catch on the ridge of the inserted armrest bun so as to position the skin thereto.  
     
     
         14 . The method of  claim 9  wherein the armrest includes a skin having an aperture proximate an opening side of the cavity, and wherein the method further comprising positioning a detent on the substrate so as to catch in the aperture.  
     
     
         15 . The method of  claim 9  configuring the armrest to include an angled flange proximate an opening in a door panel such that an angle of the flange tightens the armrest against the door panel when attached thereto so as to limit separation of a skin of the armrest from the door panel.  
     
     
         16 . The method of  claim 9  wherein the armrest includes a flexible skin having a lip extending over an opening side of the cavity, and wherein the method further comprising positioning a locating face of the substrate proximate the opening side of the first cavity when the bun is inserted into the first cavity, the lip resting on the locating face of the inserted bun if the skin is properly assembled, the lip separated from the locating face if the skin is improperly assembled.  
     
     
         17 . The method of  claim 9  wherein the substrate includes an elongated prong extending laterally from an end of the substrate into the first cavity, and wherein the method further comprising chemically bonding the foam to the prong.