DESC:FIELD
The present disclosure relates to trim panels of automobiles.
DEFINITION
As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used indicate otherwise.
Trim panel – The term trim panel refers to the dashboard, the instrument panel, the console, the door trims and the interior parts that contain the most controls and decorative parts which are formed by molding process.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Conventional trim panel of an automobile is manufactured by molding method using a core and a cavity. A mold material is made to flow into the space between the core and the cavity to form the molded trim panel. At the intersection of the core and the cavity, a sharp parting line is formed. The sharp parting line takes the form of an edge. The edge of the trim panel contacts the feet of the vehicle occupant and causes injury to the feet of the vehicle occupant. When the vehicle is in motion at high speed and in the event the vehicle experiences a bump, the severity of contact of the occupant feet with the sharp edge causes serious injury. However, the edge obstructs the seated passengers in the vehicle. Moreover, the parting line hampers the aesthetic look of the trim panel of the automobile, which is highly undesirable.
There is, therefore, felt a need of a trim panel assembly of an automobile, that alleviates the above-mentioned drawbacks.

OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
An object of the present disclosure is to provide a trim panel assembly of an automobile that improves the aesthetic look of the vehicle interior.
Another object of the present disclosure is to provide a trim panel assembly of an automobile that eliminates possibility of serious injuries to the occupants of the vehicle.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure discloses a trim panel assembly of an automobile. The trim panel assembly comprises an instrument panel attached to the structure of the automobile; and a filleted edge configured on the instrument panel. The filleted edge is located in the vicinity of the body part of the occupant, reducing probality of serious injury to the occupant, in the event the body part of the occupant contacts the instrument panel.
In a preferred embodiment, the filleted edge is located at an operative bottom portion of the instrument panel.
In a preferred embodiment, the radius of the filleted edge is alterable by altering the fillet radius profile of the insert.
In a preferred embodiment, the filleted edge imparts aesthetic look to the trim panel assembly.
The present disclosure discloses a method of making an instrument panel of a trim panel assembly. The method includes the steps of:
o providing a tooling arrangement including a core and a cavity, an insert, the insert configured with a predefined fillet radius, the predefined fillet radius having a profile to be formed on a desired filleted edge of the instrument panel;
o adjusting the insert relative to the core and the cavity, the insert positioned with the help of a fastening means attached to the insert to define a space for pouring mold material; and
o forming the instrument panel by mold flow process.
In an embodiment, the insert is integral to the core.
In another embodiment, the insert is removably attached to the core.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
The trim panel assembly of an automobile, of the present disclosure will now be described with the help of the accompanying drawing, in which:
Figure 1 shows a schematic of the existing tooling arrangement for making a trim panel assembly in the form of an instrument panel assembly, of the prior art;
Figure 2 shows an isometric view of a existing trim panel assembly comprising an instrument panel and a console, of the prior art;
Figure 3 shows a detail of figure 2;
Figure 4 shows a sectional view of figure 3;
Figure 5 show a schematic of the tooling arrangement including a core, a cavity and an insert, in accordance with an embodiment of the present disclosure;
Figure 6 shows the instrument panel, in accordance with an embodiment of the present disclosure;
Figure 7 shows a detail of figure 6; and
Figure 8 shows a filleted edge of the instrument panel, in accordance with an embodiment of the present disclosure.
LIST OF REFERENCE NUMERALS
10 – parting line of the existing instrument panel
20 – cavity of the existing tooling arrangement
30 – existing instrument panel
120 – cavity of the present disclosure
40 – core of the existing tooling arrangement
140 – core of the present disclosure
60 – existing instrument panel
160 – instrument panel of the present disclosure
80 – existing console
180 – console of the present disclosure
90 – edge of the existing instrument panel
100 – existing tooling arrangement
190 – filleted edge of the present disclosure
150 – insert of the present disclosure
195 – fastener
200 – tooling arrangement of the present disclosure
1000 – existing instrument panel assembly
2000 – instrument panel assembly of the present disclosure
DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
When an element is referred to as being "mounted on", “engaged to”,“connected to”, or “coupled to” another element, it may be directly on, engaged, connected or coupled to the other element. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.
The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region, layer or section from another component, region, layer or section. Terms such as first, second, third, etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.
Terms such as “inner,” “outer,” "beneath," "below," "lower," "above," "upper," and the like, may be used in the present disclosure to describe relationships between different elements as depicted from the figures.
Figure 1 shows an existing tooling arrangement 100 for manufacturing a trim panel 30 of an automobile. An existing trim panel assembly (not shown in figures) includes the trim panel 30. During manufacturing of the trim panel 30, a mold material is made to flow between a core 40 and a cavity 20. As the trim panel 30 is manufactured, a parting line 10 is formed. However, the parting line 10 is sharp, and there is a possibility of the passengers of the vehicle getting injured while occupying the vehicle, as a body part of the passenger contacts the parting line 10 frequently. Moreover, the aesthetic look of the existing trim panel 30 is deteriorated due to the presence of the parting line 10.
In an embodiment as shown in the figures 2-4, the existing trim panel assembly is in the form of an instrument panel assembly 1000, and the existing trim panel 30 is in the form of an instrument panel 60. The parting line 10 is in the form of an edge 90, as shown in the figure 4. The instrument panel assembly 1000 includes the instrument panel 60 and a console 80. The existing instrument panel 60 is manufactured by the existing tooling arrangement 100 as discussed above. The existing instrument panel 60 is located on an operative top side of the existing instrument panel assembly 1000. The console 80 is located on an operative bottom side of the existing instrument panel assembly 1000, as shown in the figures 2 and 3. As discussed above, the edge 90 is very sharp. The presence of the edge 90 increases possibility of the passengers getting injured as well as hampers the aesthetic look of the existing instrument panel 60. This is highly undesired.
The present disclosure aims to address the above mentioned problems of the edge sharpness and the unpleasant visual appearance of the edge 90.
Referring to the figure 5, a tooling arrangement 200 of the present disclosure is explained. The tooling arrangement 200 of the present disclosure includes a core 140, a cavity 120 and an insert 150 for making an instrument panel 160. Figure 6 shows a sectional view of the instrument panel assembly 2000, with the instrument panel 160 having a filleted edge 190. It can be observed that the filleted edge 190 reduces severity of impact on the body part of the vehicle occupant/passenger, in the event the body part of the vehicle occupant/passenger makes contact with the instrument panel 160. The insert 150 of the tooling arrangement 200 of the present disclosure is configured to be attached to the core 140. The shape of the insert 150 is constructed so as to form the filleted edge 190 on the instrument panel 160. The insert 150 when attached to the core 140 generates the desired profile of the filleted edge 190 during the forming process. Thus, the sharp parting line during the forming process is eliminated and replaced by the filleted edge 190, thereby avoiding any possibility of serious injury to the seated occupant of the vehicle. Additionally, the curvature of the filleted edge 190 imparts aesthetic look to the instrument panel assembly 2000 of the present disclosure. The filleted edge 190 is located at an operative bottom portion of the instrument panel 160.
In an embodiment of the present disclosure, the radius of the filleted edge 190 is alterable to accommodate manufacturing of the instrument panel assembly 2000 for different vehicles.
In an embodiment of the present disclosure, the insert 150 is fastened to the core 140. The fasteners are selected from the group consisting of screw, bolt, rivet, fixture. The fasteners facilitate accurate positioning of the insert 150 on the core 140. In an embodiment, a bolting arrangement 195 is shown in the figure 5 which facilitates attachment of the insert 150 to the core 140.

In another embodiment of the present disclosure, the insert 150 is affixed to the core 140 with an industrial strength glue.
In still another embodiment of the present disclosure, the trim panel assembly 2000 is in the form of a door trim.
In yet another embodiment of the present disclosure, the trim panel assembly 2000 is in the form of a tail gate.
The present disclosure discloses a method of making an instrument panel 160 of a trim panel assembly 2000. The method includes the steps of:
o providing a tooling arrangement 200 including a core 140 and a cavity 120, an insert 150, the insert 150 configured with a predefined fillet radius, the predefined fillet radius having a profile to be formed on a desired filleted edge 190 of the instrument panel 160;
o adjusting the insert 150 relative to the core 140 and the cavity 120, the insert 150 positioned with the help of a fastening means 195 attached to the insert 150 to define a space for pouring mold material; and
o forming the instrument panel 160 by mold flow process.
In an embodiment, the insert 150 is integral to the core 140.
In another embodiment, the insert 150 is removably attached to the core 140.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
The foregoing description of the specific embodiments so fully reveals the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
TECHNICAL ADVANCEMENT AND ECONOMIC SIGNIFICANCE
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of an trim panel assembly of a vehicle, that:
o eliminates possibility of injury to the occupant; and
o increases aesthetic appearance of the instrument panel assembly.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, or step, or group of elements, or steps, but not the exclusion of any other element, or step, or group of elements, or steps.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.
,CLAIMS:WE CLAIM:
1. A trim panel assembly (2000) of an automobile, said assembly (2000) comprising:
o an instrument panel (160) attached to the structure of the automobile; and
o a filleted edge (190) configured on said instrument panel (160), said filleted edge (190) located in the vicinity of the body part of the occupant, reducing probality of serious injury to the occupant, in the event the body part of the occupant contacts said instrument panel (160).
2. The assembly (2000) as claimed in claim 1, wherein said filleted edge (190) is located at an operative bottom portion of said instrument panel (160).
3. The assembly (2000) as claimed in claim 1, wherein the radius of said filleted edge (190) is alterable.
4. The assembly (2000) as claimed in claim 1, wherein said filleted edge (190) imparts aesthetic look to said trim panel assembly (2000).
5. A method of making an instrument panel (160) of a trim panel assembly (2000) as claimed in claim 1, said method including the steps of:
o providing a tooling arrangement (200) including a core (140) and a cavity (120), an insert (150), said insert (150) configured with a predefined fillet radius, the predefined fillet radius having a profile to be formed on a desired filleted edge (190) of said instrument panel (160);
o adjusting said insert (150) relative to said core (140) and said cavity (120), said insert (150) positioned with the help of a fastening means (195) attached to said insert (150) to define a space for pouring mold material; and
o forming said instrument panel (160) by mold flow process.
6. The method as claimed in claim 5, wherein said insert (150) is integral to said core (140).
7. The assembly (2000) as claimed in claim 1, wherein said insert (150) is removably attached to said core (140).
Dated this 12th day of June, 2023

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
of R.K. DEWAN & CO.
Authorized Agent of Applicant

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT CHENNAI