Method of Making An Automotive Trim Part With Applique

Abstract

The present invention provides for an improved trim part, e.g. a bolster or trim plate, with integrated appliqué for use in a trim assembly, and to a continuous two-shot molding operation that may be performed utilizing a single mold assembly. In an exemplary embodiment, the trim part, i.e. a bolster, includes a substrate formed by injecting a first material into a first shot mold cavity in a first shot of a molding operation. An appliqué is provided in a second shot mold cavity then a cover is formed between the substrate and appliqué by injecting into a mold chamber a second foamed material in a second shot of the molding operation. The formed cover is integrally molded to at least a portion of the substrate and the appliqué to form a trim part with integrated appliqué.

1 . A method of forming an automotive trim part with an integrated appliqué in a two-shot molding operation, comprising: 
 molding a substrate by injecting a first material in a first shot of the molding operation;    providing an appliqué;    forming a mold chamber about at least a portion of the substrate and the appliqué; and    molding a cover intermediate the portion of the substrate and the appliqué by injecting into the mold chamber a second foamed material in a second shot of the molding operation, the cover being molded to at least the portion of the substrate and the appliqué to form the trim part with an integrated appliqué.    
   
   
       2 . The method of  claim 1 , wherein the step of molding a substrate by injecting a first material includes molding the substrate by injecting a thermoplastic polymer; and wherein the step of molding a cover by injecting a second foamed material includes molding the cover by injecting a foamed thermoplastic polymer.  
   
   
       3 . The method of  claim 1 , wherein the step of molding a substrate by injecting a first material includes molding the substrate by injecting a thermoplastic polymer; and wherein the step of molding a cover by injecting a second foamed material includes molding the cover by injecting one of a foamed thermoplastic elastomer and foamed polypropylene.  
   
   
       4 . The method of  claim 1 , wherein the step of providing an appliqué comprises providing the appliqué including a decorative material.  
   
   
       5 . The method of  claim 1 , wherein the step of providing an appliqué comprises providing the appliqué having a symbol thereon.  
   
   
       6 . The method of  claim 1 , wherein the formed trim part with an integrated appliqué is one of a trim plate and a bolster with an integrated appliqué.  
   
   
       7 . A method of forming an automotive trim part with an integrated appliqué in a continuous two-shot molding operation, comprising: 
 providing a mold assembly having first and second shot mold cavities;    molding a substrate by injecting a first material into the first shot mold cavity of the mold assembly in a first shot of the molding operation;    providing the second shot mold cavity with an appliqué;    moving the substrate from the first shot mold cavity to the second shot mold cavity by using at least a portion of the mold assembly;    forming a mold chamber about at least a portion of the substrate and the appliqué within the second shot mold cavity of the mold assembly; and    molding a cover intermediate the portion of the substrate and the appliqué by injecting into the mold chamber a second foamed material in a second shot of the molding operation, the cover being molded to at least the portion of the substrate and the appliqué to form the trim part with an integrated appliqué.    
   
   
       8 . The method of  claim 7 , wherein the step of molding a substrate by injecting a first material includes molding the substrate by injecting a thermoplastic polymer; and wherein the step of molding a cover by injecting a second foamed material includes molding the cover by injecting a foamed thermoplastic polymer.  
   
   
       9 . The method of  claim 7 , wherein the step of molding a substrate by injecting a first material includes molding the substrate by injecting a thermoplastic polymer; and wherein the step of molding a cover by injecting a second foamed material includes molding the cover by injecting a foamed thermoplastic elastomer or foamed polypropylene.  
   
   
       10 . The method of  claim 7 , wherein the step of providing an appliqué comprises providing the appliqué including a decorative material.  
   
   
       11 . The method of  claim 7 , wherein the step of providing an appliqué comprises providing the appliqué having a symbol thereon.  
   
   
       12 . The method of  claim 7 , wherein the formed trim part with an integrated appliqué is one of a trim plate and a bolster with an integrated appliqué.  
   
   
       13 . The method of  claim 7 , wherein the step of providing a mold assembly having first and second shot mold cavities comprises providing a mold assembly having first and second shot mold cavities and a core having at least one male portion adapted to mate with each cavity, the core further being adapted to rotate; 
 wherein the step of molding a substrate comprises molding the substrate by mating the at least one male portion with the first shot mold cavity and injecting the first material into the first shot mold cavity in the first shot of the molding operation;    wherein the step of moving the substrate comprises rotating the substrate on the at least one male portion of the core from the first mold cavity to the second mold cavity; and    wherein the step of forming a mold chamber comprises forming the mold chamber about at least a portion of the substrate and the appliqué within the second shot mold cavity of the mold assembly by mating the at least one male portion with the second shot mold cavity to mold the cover therebetween in the second shot of the molding operation.    
   
   
       14 . The method of  claim 13 , wherein the step of rotating the substrate comprises rotating the substrate about a horizontal axis to move the substrate from the first shot mold cavity to the second shot mold cavity.