Description:Field of the invention

[0001] The present invention relates to an interior panel of a vehicle. More specifically, the present invention relates to a trim panel for a vehicle interior having improved aesthetics without compromising the mechanical stability of a locking portion.

Background of the invention:

[0002] Generally, a vehicle interior panel or a vehicle trim panel with flanges and a locking clip structure is commonly used to secure and lock a utility member such as a casing of the door handle or a glove box or similarly designed arrangements. Particularly, the locking clip structure extends from the trim panel along the flange. The locking clip structure extending from the trim panel creates a surface contact with the flange which forms a larger thickness. Presently, the trim panel is manufactured using an injection moulding process, and the common defect of the injection moulding process is the sink mark which occurs at a portion having a larger thickness.

[0003] The sink marks are formed in thicker areas due to varying cooling rates across the panel or insufficient cooling while the trim panel is in the mould. The sink marks are depressions on the visible surface of the part which is an unwanted effect on any aesthetic part like an interior panel or decorative panel of the dashboard.

[0004] Presently, the locking clip structure is extending from the trim panel along the flange to engage with a dashboard panel or any utility member. So, the locking clip structure needs to be sufficiently stable and have good structural strength. Hence, reducing the thickness of the locking portion will reduce the mechanical stability of the locking portion.

[0005] Therefore, there is a requirement for a trim panel for a vehicle interior having improved aesthetics with higher mechanical stability and structural strength.

Objects of the invention

[0006] It is an object of the present invention to provide a trim panel for a vehicle interior having improved aesthetics devoid of any sink marks which is structurally strong to hold the interior panel.

Summary of the invention:

[0007] According to the present invention, there is provided with a trim panel for a vehicle interior, the trim panel includes a molded plastic carrier with a flange portion extending from an edge of the molded plastic carrier, and a clip portion arrange adjacent to the flange portion on the molded plastic carrier. The flange portion may be extending substantially perpendicularly from an edge of a plain surface of the molded plastic carrier. The clip portion may be adapted to engage with a utility member. The molded plastic carrier may be a door panel of the vehicle and the utility member may be a casing of the door handle. The clip portion may include at least two support legs spaced apart from each other, the support legs may extend from the plain surface of the molded plastic carrier and overlap with the flange portion. Specifically, a width portion of the support legs may abut and overlap with an inner surface of the flange portion. Further, the clip portion may include a head portion which extends from the support legs away from the flange portion. The head portion may partially overlap the flange portion.

[0008] In another aspect of the present invention, a length portion of the support legs may gradually decrease from the plain surface to an upper end of the inner surface of the flange portion.

[0009] The head portion may be an overhang from the inner surface of the flange portion configuring a space between the head portion and the plain surface of the molded plastic carrier. Further, the head portion may be having an opening to engage with a hook portion of the utility member of the vehicle interior.

[0010] The trim panel for a vehicle interior may be manufactured using an injection molding process. The injection molding process may include following steps.

[0011] At first, an injection molding tool having a lifter may be provided to manufacture the trim panel. The lifter may be adapted to form the head portion of the clip portion, the support legs, and the space between the head portion and the plain surface. The lifter may include a first protruding portion to form an opening of the head portion of the trim panel. Further, the lifter may include a second protruding portion to form a space between the head portion and the plain surface. The first protruding portion may be having a width. The width of the first protruding portion may be smaller than a width of the second protruding portion.

[0012] In another aspect of the invention, the lifter may include at least two undercut portions spaced apart from each other, wherein the two undercut portions may be extending away from the second protruding portion to form the support legs of the clip portion.

[0013] In one more aspect of the present invention, the lifter may be adapted to form at least two clip portions. The lifter may include a first lifter portion and a second lifter portion extending sideways and adapted to form two clip portions. The first lifter portion and the second lifter portion may be adapted to form the head portion with the opening, at least two support legs of the clip portion, and the space between the head portion and the plain surface of the molded plastic carrier.

[0014] After providing the injection molding tool and the lifter, the injection molding tool along with the lifter may be closed to form a cavity of the trim panel for the vehicle. After that molten plastic may be injected into the cavity to fill the shape of the trim panel. Then, the molten plastic is cured to solidify the trim panel. In the end, when the molten plastic is cured, the injection molding tool is opened along with the lifter to remove the trim panel for the vehicle interior.

Brief description of drawings:

[0015] The advantages and features of the present invention will be understood better with reference to the following detailed description and claims taken in conjunction with the accompanying drawings, wherein like elements are identified with like symbols, and in which:

[0016] Figure 1a shows a perspective view of a trim panel having a clip in accordance with the present invention;

[0017] Figure 1b shows a sectional view of the trim panel shown in figure 1 in accordance with the present invention;

[0018] Figure 2a shows a perspective view of a trim panel in accordance with another embodiment of the present invention;

[0019] Figure 2b shows a sectional view of a trim panel in accordance with the embodiment shown in figure 2a;

[0020] Figure 3 shows a perspective view of the trim panel engaged with a utility member in accordance with the present invention;

[0021] Figure 4a shows a perspective view of a lifter in accordance with the present invention;

[0022] Figure 4b shows a sectional view of the lifter shown in figure 4a in accordance with the present invention;

[0023] Figure 5 shows a perspective view of a lifter in accordance with another embodiment of the present invention;

[0024] Figure 6a and 6b shows a perspective view of a lifter in accordance with one more embodiment of the present invention; and

[0025] Figure 7 shows a flowchart of an injection molding process to manufacture the trim panel for a vehicle interior in accordance with the present invention.

Detailed description of the invention

[0026] An embodiment of this invention, illustrating its features, will now be described in detail. The words "comprising," "having," "containing," and "including," and other forms thereof, are intended to be equivalent in meaning and be open-ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items.

[0027] The terms “first,” “second,” and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another, and the terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.

[0028] The disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms.

[0029] The present invention provides a trim panel for a vehicle interior. The trim panel is having an improved locking portion which is provided in a way that formation of the sink marks can be prevented. With the proposed process and arrangement of the locking portion, the sink marks can be removed along with maintaining the mechanical stability of the locking portion.

[0030] Referring now to figures 1a, 1b, and 3, a trim panel (100) for a vehicle interior in accordance with the present invention is illustrated. The trim panel (100) includes a molded plastic carrier (10) with a flange portion (20) and a clip portion (30). The molded plastic carrier (10) is adapted to engage with a utility member (50). In the present embodiment of the invention, the utility member (50) is a casing of the door handle and the molded plastic carrier (10) is a door panel of the vehicle. In another embodiment, the utility member (50) is but not limited to a main dashboard, or an internal roof of the vehicle or the like. The molded plastic carrier (10) is but not limited to a decorative part or a steering wheel part or a door lining or a car roof lining or the like.

[0031] Referring again to figures 1a, and 1b, the molded plastic carrier (10) is having a plain surface (11) that extends throughout its entirety. The flange portion (20) of the trim panel (100) extends from an edge of the molded plastic carrier (10), specifically, the flange portion (20) extends substantially perpendicularly from an edge of the plain surface (11) of the molded plastic carrier (10). The flange portion (20) is rectangular in shape and extends entirely around the edge of the plain surface (11). The flange portion (20) is having an inner surface (22) substantially perpendicular to the plain surface (11), and an upper end (21) away from the plain surface (11).

[0032] Further, the clip portion (30) which is having a thickness (343) is arranged adjacent to the flange portion (20) of the molded plastic carrier (10) of the trim panel (100). The clip portion (30) is adapted to engage with the utility member (50). The clip portion (30) is having at least two support legs (32a, 32b) extending from the plain surface (11) and at least a portion of the at least two support legs (32a, 32b) abut and overlap with the inner surface (22) of the flange portion (20). The present embodiment is shown to have only two support legs (32a, 32b). These support legs (32a, 32b) serve as structural extensions that facilitate the attachment of the clip portion (30) to the plastic carrier (10) and provide stability and support. The support legs (32a, 32b) are spaced apart from each other overlapping the flange portion (20) of the trim panel (100). In an embodiment of the present invention, more than two support legs can extend from the plain surface (11) of the plastic carrier (10) to provide more stability and support.

[0033] In the present embodiment, the support legs (32a, 32b) extend from the plain surface (11), and away from the inner surface (22) of the flange portion (20). The support legs (32a, 32b) are having a length portion (323) elongated perpendicular to the flange portion (20), and a width portion (322) stretched perpendicular to the length portion (323) of the support legs (32a, 32b). The length portion (323) of the support legs (32a, 32b) is equal to the thickness (343) of the clip portion (30). The support legs (32a, 32b) overlap the flange portion (20), especially the width portion (322) of the support legs (32a, 32b) abuts and overlaps the inner surface (22) of the flange portion (20).

[0034] In another embodiment, as shown in figures 2a, and 2b, the length portion (323) of the support legs (32a, 32b) gradually decreases from the plain surface (11) to the upper end (21) of the inner surface (22) of the flange portion (20).

[0035] Further, the clip portion (30) is having a head portion (34) which extends from the support legs (32a, 32b). The head portion (34) extends across the support legs (32a, 32b) and partially overlaps with the inner surface (22) of the flange portion (20). The head portion (34) partially overlaps with the inner surface (22) of the flange portion (20) but does not contact the plain surface (11) of the molded plastic carrier (10). The head portion (34) overhangs from the inner surface (22) of the flange portion (20) configuring a space (25) between the head portion (34) and the plain surface (11) of the molded plastic carrier (10). The space (25) between the head portion (34) and the plain surface (11) ensures that the head portion (34) does not completely overlap with the flange portion (20). By avoiding complete overlap, there is a reduction in a material volume. The material volume is reduced to maintain a consistent thickness of the flange portion (20) which removes the sink mark formation due to the varying cooling rate of the trim panel (100) while manufacturing the trim panel (100).

[0036] In another embodiment of the present invention, a clip portion (30) is arranged on a flange portion (20) without providing the support legs (32a, 32b). Specifically, the clip portion (30) is extending from an upper end (21) of the flange portion (20). This prevents the overlapping of the clip portion (30) on an inner surface (22) of the flange portion (20) and also prevents the overlapping of the support legs (32a, 32b) on a plain surface (11) and the inner surface (22) which reduces the material volume. The material volume is reduced to maintain the consistent thickness of the flange portion (20). The consistent thickness of the flange portion (20) helps to remove the sink mark formation while manufacturing the trim panel (100).

[0037] Further, the head portion (34) is having an opening (341) to engage with the utility member (50). Specifically, the opening (341) in the head portion (34) is intended to connect with a hook portion (51) of the utility member (50). The hook portion (51) extends from the utility member (50) and engages with the opening (341) in the head portion (34) to securely hold the trim panel (100) in place. The hook portion (51) is adapted to snap-fit with the clip portion (30) of the trim panel (100). The engagement of the hook portion (51) with the opening (341) in the head portion (34) allows for the trim panel (100) to be firmly held in position.

[0038] Further, an injection molding process (300) is provided to manufacture the trim panel (100) for the vehicle interior. For the sake of brevity, the injection moulding process (300) is described in conjunction with the arrangement of the trim panel (100). The process (300) includes the following steps:

[0039] The process (300) starts at step (310).

[0040] At step (320), an injection molding tool is provided to manufacture the trim panel (100). Now referring to figures 4a, and 4b, the injection molding tool includes a lifter (200) to form the clip portion (30) of the molded plastic carrier (10). Specifically, the lifter (200) is adapted to form the head portion (34) of the clip portion (30) with the opening (341), at least two support legs (32a, 32b) of the clip portion (30), and the space (25) between the head portion (34) and the plain surface (11) of the molded plastic carrier (10). The lifter (200) includes a plain face (210) which serves as the foundation for forming the head portion (34) of the clip portion (30). Further, the lifter (200) includes a first protruding portion (220) that forms the opening (341) in the head portion (34) of the clip portion (30). The first protruding portion (220) extends outward or away from the plain face (210) of the lifter (200).

[0041] Furthermore, the lifter (200) is having a second protruding portion (230) that extends from a bottom of the plain face (210) of the lifter (200). The second protruding portion (230) forms the space (25) between the head portion (34) and the plain surface (11). The first protruding portion (220) is having a width which is smaller than a width of the second protruding portion (230).

[0042] In another embodiment of the present invention as shown in figure 5, a lifter (200) includes at least two undercut portions (240a, 240b) spaced apart from each other. The undercut portions (240a, 240b) recess away from a protruded portion (230) along the sides of the lifter (200). The undercut portions (240a, 240b) are provided to form the support legs (32a, 32b) of the clip portion (30) shown in figures 2a, and 2b . In an embodiment, the undercut portions (240a, 240b) are provided at extreme ends of the lifter (200). A person skilled in the art can configure more than two undercut portions (240a, 240b) spaced between the undercut portions (240a, 240b) which are provided at the extreme ends of the lifter (200).

[0043] In one more embodiment of the present invention as shown in figures 6a, and 6b, an injection molding tool includes a lifter (200) that is adapted to form at least two clip portions. The lifter (200) includes a first lifter portion (250a) and a second lifter portion (250b) extending sideways away from each other. The first lifter portion (250a) and the second lifter portion (250b) are adapted to form two clip portions (30) which include the head portion (34) with the opening (341), at least two support legs (32a, 32b) of the clip portion (30), and the space (25) between the head portion (34) and the plain surface (11) of the molded plastic carrier (10). The first lifter portion (250a) and the second lifter portion (250b) include corresponding plain faces (210a, 210b) to serve as the foundation for forming the head portion (34), first protruding portions (220a, 220b) to form the opening (341) in the head portion (34) of the clip portion (30), and second protruding portions (230a, 230b) to form the space (25) between the head portion (34) and the plain surface (11).

[0044] At step (330), the injection molding tool is closed along with the lifter (200) to form a cavity. The cavity is having the shape of the trim panel (100).

[0045] At step (340), the injection molding tool is injected with molten plastic. The molten plastic is injected using a nozzle (not shown) to fill the cavity with the molten plastic. It may be obvious to a person skilled in the art to use any type of plastic to inject inside the cavity.

[0046] At step (350), the molten plastic is allowed to cure and solidify within the cavity to form the trim panel (100). The support legs (32a, 32b) and the head portion (34) are provided with a space (25) between the head portion (34) and the plain surface (11) which reduces the material volume at the flange portion (20). The support legs (32a, 32b) and the head portion (34) are not in surface contact with the flange portion (20) which allows the flange portion (20) to solidify with the constant cooling rate and avoids the formation of sink marks.

[0047] At step (360), after curing the molten plastic, the injection molding tool is opened along with the lifter (200). After opening (341) the injection tool, the trim panel (100) is ejected from the injection molding tool. The trim panel (100) that is extracted from the injection molding tool comprises the molded plastic carrier (10) having the flange portion (20), and the clip portion (30) adapted to securely engage with the utility member (50). The trim panel (100) extracted from the injection molding tool is devoid of any sink marks.

[0048] The process (300) ends at step (370).

[0049] Therefore, the advantage of the present invention is to provide a trim panel (100) for a vehicle interior with improved aesthetics. The trim panel (100) is having the support legs (32a, 32b) extending from the plain surface (11) and the head portion (34) extending away from the flange portion (20) to configure the space (25) between the head portion (34) and the plain surface (11) to maintain the constant thickness of the flange portion (20). Due to the constant thickness, the defects like sink marks are avoided and an improved aesthetic of the trim panel (100) is achieved. The sink marks are avoided without compromising the mechanical stability of the clip portion (30).

[0050] The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously, many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to explain the principles of the present invention best and its practical application, to thereby enable others skilled in the art to best utilise the present invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omission and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the spirit or scope of the claims of the present invention.
, Claims:We Claim:
1. A trim panel (100) for a vehicle interior, the trim panel (100) comprises:
a molded plastic carrier (10) including:
a flange portion (20); and
a clip portion (30) arranged adjacent to the flange portion (20) and adapted to engage with a utility member (50);
wherein the clip portion (30) includes:
at least two support legs (32a, 32b) spaced apart from each other; and
a head portion (34) extending from at least two support legs (32a, 32b) and away from the flange portion (20).

2. The trim panel (100) as claimed in claim 1, wherein the flange portion (20) is extending substantially perpendicularly from an edge of a plain surface (11) of the molded plastic carrier (10), wherein at least two support legs (32a, 32b) of the clip portion (30) are extending from the plain surface (11) of the molded plastic carrier (10) and at least a width portion (322) of the at least two support legs (32a, 32b) abut and overlap with an inner surface (22) of the flange portion (20).

3. The trim panel (100) as claimed in claim 1, wherein the head portion (34) is an overhang from an inner surface (22) of the flange portion (20) configuring a space (25) between the head portion (34) and a plain surface (11) of the molded plastic carrier (10).

4. The trim panel (100) as claimed in claim 2, wherein a length portion (323) of the support legs (32a, 32b) gradually decreases from the plain surface (11) to an upper end (21) of the inner surface (22) of the flange portion (20).

5. The trim panel (100) as claimed in claim 1, wherein the head portion (34) includes an opening (341) to engage with a hook portion (51) of the utility member (50) of the vehicle interior.

6. The trim panel (100) as claimed in claim 1, wherein the molded plastic carrier (10) is a door panel of a vehicle and the utility member (50) is a casing of the door handle.

7. An injection molding process (300) for manufacturing a trim panel (100) for a vehicle, wherein the trim panel (100) including a molded plastic carrier (10) with a flange portion (20), and a clip portion (30) for engaging with a utility member (50), comprising steps of:
providing an injection molding tool including a lifter (200), the lifter (200) is adapted to form the clip portion (30) which includes a head portion (34) with an opening (341), at least two support legs (32a, 32b) of the clip portion (30), and a space (25) between the head portion (34) and a plain surface (11) of the molded plastic carrier (10);
closing the injection molding tool along with the lifter (200) to form a cavity;
injecting molten plastic into the cavity;
curing the molten plastic; and
opening the injection molding tool along with the lifter (200) to eject the trim panel (100) for the vehicle.

8. The injection molding process (300) as claimed in claim 7, wherein the lifter (200) includes a first protruding portion (220) and second protruding portion (230) to form an opening (341) of the head portion (34) and to form a space (25) between the head portion (34) and the plain surface (11) respectively.
9. The injection molding process (300) as claimed in claim 8, wherein a width of the first protruding portion (220) is smaller than a width of the second protruding portion (230).

.

10. The injection molding process (300) as claimed in claim 7, wherein the lifter (200) includes at least two undercut portions (240a, 240b) spaced apart from each other, wherein the at least two undercut portions (240a, 240b) are extending away from a protruded portion (230) to form the at least two support legs (32a, 32b) of the clip portion (30).

11. The injection molding process (300) as claimed in claim 7, wherein the lifter (200) includes a first lifter portion (250a) and a second lifter portion (250b) extending sideways and adapted to form two clip portions which includes the head portion (34) with the opening (341), at least two support legs (32a, 32b) of the clip portion (30), and the space (25) between the head portion (34) and the plain surface (11) of the molded plastic carrier (10).