Automotive armrest with soft feel and method of making the same

Abstract

The present invention provides for an improved armrest with a soft feel for use in a trim assembly, and to a continuous two-shot molding operation that may be continuously performed utilizing a single mold assembly. In an exemplary embodiment, a trim assembly includes an integrated armrest formed by injecting a first material into a first shot mold cavity in a first shot of a molding operation. An armrest cover is molded to at least a portion of the armrest by injecting into a mold chamber a second foamed material in a second shot of the molding operation to provide the armrest with a soft feel. The second foamed material includes a foamed material that produces a soft, outer skin and a light, cellular inner core such that when a force is applied to the cover, the skin will deform and compress the inner core, providing a soft-touch feel to the armrest.

1 . A method of forming an automotive armrest with soft feel in a: continuous two-shot molding operation, comprising:
 providing a mold assembly having first and second shot mold cavities;   molding an armrest by injecting a first material into the first shot mold cavity of the mold assembly in a first shot of the molding operation;   moving the armrest 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 armrest within the second shot mold cavity of the mold assembly; and   molding an armrest cover by injecting into the mold chamber a second foamed material in a second shot of the molding operation, the cover being molded to the at least a portion of the armrest to provide the armrest with a soft feel.   
   
   
       2 . The method of  claim 1 , wherein the step of molding an armrest comprises molding a substrate having an integrated armrest by injecting the first material in the first shot of the molding operation, and wherein the step of moving the armrest comprises moving the substrate having the integrated armrest from the first shot mold cavity to the second shot mold cavity by using the at least a portion of the mold assembly to mold the cover to the at least a portion of the armrest to provide the armrest with the soft feel. 
   
   
       3 . The method of  claim 2 , wherein the step of molding the substrate having an integrated armrest comprises molding a door trim panel having the integrated armrest. 
   
   
       4 . The method of  claim 1 , wherein the first material includes a thermoplastic polymer and the second foamed material includes a foamed thermoplastic polymer. 
   
   
       5 . The method of  claim 4 , wherein the foamed thermoplastic polymer includes one of a foamed thermoplastic elastomer and foamed polypropylene. 
   
   
       6 . The method of  claim 1 , 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 an armrest comprises molding the armrest 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 armrest from the first shot mold cavity to the second shot mold cavity by using at least a portion of the mold assembly comprises rotating the armrest 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 the at least a portion of the armrest 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 armrest cover in the second shot of the molding operation.   
   
   
       7 . The method of  claim 6 , wherein the step of rotating the armrest comprises rotating the armrest about a horizontal axis to move the armrest from the first mold cavity to the second mold cavity. 
   
   
       8 . A method of forming an automotive armrest with soft feel in a continuous two-shot molding operation, comprising:
 molding an armrest by injecting a first material in a first shot of the molding operation;   forming a mold chamber about at least a portion of the armrest; and   molding an armrest cover by injecting into the mold chamber a second foamed material in a second shot of the molding operation, the cover being molded to the at least a portion of the armrest to provide the armrest with a soft feel.   
   
   
       9 . The method of  claim 8 , wherein the first material includes a thermoplastic polymer and the second foamed material includes a foamed thermoplastic polymer. 
   
   
       10 . The method of  claim 9 , wherein the foamed thermoplastic polymer includes one of a foamed thermoplastic elastomer and foamed polypropylene. 
   
   
       11 . The method of  claim 8 , wherein the step of molding an armrest comprises molding a substrate having an integrated armrest by injecting the first material in the first shot of the molding operation. 
   
   
       12 . The method of  claim 11 , wherein the step of molding the substrate having the integrated armrest comprises molding a door trim panel having the integrated armrest.