阅读说明：本技术 使用注塑可移除虚设外皮形成包裹部件的方法 (Method of forming a wrapped component using injection molding removable dummy skin ) 是由 巴里·布朗 马努基·帕特纳拉 于 2019-07-10 设计创作，主要内容包括：本公开提供了“使用注塑可移除虚设外皮形成包裹部件的方法”。一种形成包裹部件的方法,包括：将注塑外皮定位在模具中；抵靠注塑外皮形成现场发泡(FIP)泡沫基板；从FIP泡沫基板移除注塑外皮；将外部包裹物结合到FIP泡沫基板；以及重复使用注塑聚烯烃外皮以形成另外的FIP泡沫基板。可将分隔层结合到FIP泡沫基板与外部包裹物之间并与两者结合。注塑外皮可由聚烯烃聚合物形成,并且可以是诸如热塑性硫化橡胶的热塑性弹性体。FIP泡沫基板可以是FIP聚氨酯泡沫基板,并且外部包裹物可以是皮革包裹物或人造皮革包裹物。注塑外皮是能重复使用的并且可在被替换注塑外皮替换之前使用预定次数,例如,至少十次。(The present disclosure provides a "method of forming a wrapped component using an injection molded removable dummy skin. A method of forming a wrapped component, comprising: positioning the injection molded skin in a mold; forming a foam-in-place (FIP) foam substrate against the injection molded skin; removing the injection molded skin from the FIP foam substrate; bonding an outer wrap to the FIP foam substrate; and reusing the injection molded polyolefin skin to form additional FIP foam substrate. A spacer layer may be bonded between and to both the FIP foam substrate and the outer wrap. The injection molded skin may be formed from a polyolefin polymer and may be a thermoplastic elastomer such as a thermoplastic vulcanizate. The FIP foam substrate may be a FIP polyurethane foam substrate, and the outer wrap may be a leather wrap or an artificial leather wrap. The injection molded skin is reusable and may be used a predetermined number of times, for example, at least ten times, before being replaced by a replacement injection molded skin.)

1. A method of forming a wrapped component, comprising:

positioning an injection molded skin in a foam-in-place (FIP) mold;

forming a FIP foam substrate against the injection molded skin;

removing the injection molded skin from the FIP foam substrate; and

bonding an outer wrap to the FIP foam substrate to form a wrapped component, wherein the injection molded skin is subsequently used to form another wrapped component.

2. The method of claim 1, wherein the injection molded skin comprises an injection molded polyolefin skin formed of a thermoplastic elastomer (TPE) and preferably a thermoplastic vulcanizate (TPV).

3. The method of claim 2, wherein the injection molded skin comprises a thickness between about 0.5mm and about 1.5mm, and the FIP foam substrate comprises a FIP polyurethane foam substrate having a thickness between about 2.0mm and about 20.0 mm.

4. The method of claim 1, wherein the outer wrap comprises a leather wrap or an artificial leather wrap.

5. The method of any one of claims 1-4, further comprising: a replacement injection molded skin is formed after using the injection molded skin a predetermined number of times.

6. The method of any one of claims 1-4, further comprising: bonding a spacer layer between and to the FIP foam substrate and the outer wrap.

7. A method of forming a plurality of instrument panels, comprising the steps of:

a. positioning an injection molded removable skin formed from a polyolefin polymer in a foam-in-place (FIP) mold;

b. forming a FIP polyurethane foam substrate between a substrate backing layer and the injection molded removable skin;

c. removing the injection molded removable skin from the FIP polyurethane foam substrate and forming an outer surface on the FIP polyurethane foam substrate;

d. bonding an outer wrap to the outer surface of the FIP polyurethane foam substrate to form an instrument panel; and

e. repeating steps a-d using the same injection molded removable skin to form additional instrument panels.

8. The method of claim 7, further comprising: a replacement injection molded removable skin is formed after a predetermined number of uses of the injection molded skin.

9. The method of claim 8, wherein the replacement injection molded removable skin is formed with a cycle time of less than about 120 seconds.

10. The method of claim 7, wherein the injection molded removable skin is formed of a thermoplastic elastomer (TPE) and preferably a thermoplastic vulcanizate (TPV).

11. The method of claim 7, wherein the injection molded removable skin comprises a thickness between about 0.5mm and about 1.5 mm.

12. The method of claim 7, wherein the FIP polyurethane foam substrate comprises a thickness of between about 2.0mm and about 20.0 mm.

13. The method of claim 7, wherein the outer wrap comprises a leather wrap.

14. The method of claim 7, wherein the outer wrap comprises an artificial leather wrap.

15. The method of any one of claims 7-14, wherein step d further comprises: bonding a separation layer to the outer surface of the FIP polyurethane foam substrate and bonding the outer wrap to the separation layer to form the instrument panel such that the outer wrap is bonded to the outer surface of the FIP polyurethane foam substrate through the separation layer.

Technical Field

The present disclosure relates to a wrapped component having an outer wrap bonded to a substrate, and in particular, to forming a wrapped component having an outer wrap bonded to a substrate using a reusable injection-molded removable dummy skin.

Background

The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

Components such as vehicle dashboards, vehicle center consoles, furniture armrests, and the like are typically manufactured by forming a substrate having a desired shape and covering or "wrapping" the substrate with an outer wrap. The base or economic model of such a "wrapped component" may include an outer wrap (also referred to herein as a "skin") formed from, for example, polyvinyl chloride (PVC), while the high-end or luxury model of the wrapped component may include an outer wrap formed from leather, synthetic leather, or the like. In addition, the luxury model may include a separation layer beneath the outer wrap to ensure that the wrap component has a 'soft' or 'comfortable' feel and appearance.

A luxury model of the wrapped component may be formed by wrapping the economic model with additional layers. For example, a spacer layer and a leather layer may be applied or wrapped onto the PVC skin of the economic model wrapping component to form a luxurious model of the wrapped component. In such cases, the PVC skin is referred to as a "dummy" skin or dummy layer because it does not function other than to provide a surface for the separation and leather layers to be applied. However, the dummy skin increases the weight and cost of the wrapped component.

The present disclosure addresses these problems of wrapping components using a dummy skin.

Disclosure of Invention

In one form of the present disclosure, a method of forming a wrapped component includes: positioning the injection molded skin in a mold; forming a foam-in-place (FIP) foam substrate against the injection molded skin; removing the injection molded skin from the FIP foam substrate; and bonding an outer wrap to the FIP foam substrate to form a wrapped component. In some aspects of the disclosure, a spacer layer is bonded to the FIP foam substrate and the outer wrap is bonded to the spacer layer. The injection molded skin is reusable and then positioned in the mold to form another wrapped component. The injection molded skin may have a thickness between about 0.5 millimeters (mm) and about 1.5mm and may be formed from a polyolefin polymer. For example, the injection molded skin may be a thermoplastic elastomer (TPE), such as a thermoplastic vulcanizate (TPV). The FIP foam substrate may be formed of polyurethane and may have a thickness between about 2.0mm and about 20.0 mm. The outer wrap may be a leather wrap or an artificial leather wrap. The method may include forming a replacement injection molded skin after using the injection molded skin a predetermined number of times. The replacement injection molded skin may be formed with a cycle time of less than about 120 seconds, allowing replacement of the injection molded skin to occur in a timely manner.

In another form of the present disclosure, a method of forming a plurality of instrument panels includes the steps of: (a) positioning an injection molded removable skin formed from a polyolefin polymer in a mold; (b) forming a foam-in-place (FIP) polyurethane foam substrate between a substrate backing layer and the injection molded removable skin; (c) forming an outer surface on the FIP polyurethane foam substrate by removing the injection-molded removable skin from the FIP polyurethane foam substrate; (d) bonding an outer wrap to the outer surface of the FIP polyurethane foam substrate to form an instrument panel; and (e) repeating steps a-d using the same injection molded removable skin to form additional instrument panels. The method can include forming a replacement injection molded removable skin formed from a polyolefin polymer after using the injection molded removable skin a predetermined number of times. The injection molded removable skin may be formed with a cycle time of less than about 120 seconds and formed from a thermoplastic elastomer (TPE), such as a thermoplastic vulcanizate (TPV). The injection molded removable skin may have a thickness between about 0.5mm and about 1.5mm, and the FIP polyurethane foam substrate may have a thickness between 2.0mm and about 20.0 mm. The outer wrap may be formed of leather or synthetic leather. In some aspects of the present disclosure, a separation layer is bonded to the outer surface of the FIP polyurethane foam substrate and the outer wrap is bonded to the separation layer such that the outer wrap is bonded to the outer surface through the separation layer.

In yet another form of the present disclosure, a method of forming a plurality of instrument panels having an exterior leather or synthetic leather surface comprises: an injection molded removable skin formed from a polyolefin polymer and a substrate backing layer are positioned in a Foam In Place (FIP) mold. In some aspects of the present disclosure, the injection molded removable skin is spaced apart from the substrate backing layer by a distance of between about 2.0mm and about 20.0 mm. An instrument panel preform is formed by forming and bonding a FIP polyurethane foam substrate between the substrate backing layer and the injection molded removable skin. Removing the preform from the FIP mold and removing the injection removable skin from the FIP polyurethane foam substrate. Removing the injection molded removable skin from the FIP polyurethane foam substrate forms an outer surface on the FIP polyurethane foam substrate, and the outer wrap may be bonded to the outer surface to form an instrument panel. In some aspects of the present disclosure, a separation layer may be bonded to the outer surface of the FIP polyurethane foam substrate and the outer wrap may be bonded to the separation layer to form the instrument panel. The step of forming the instrument panel may be repeated using the same injection molded removable skin to form at least 10 additional instrument panels, namely the steps of: (a) positioning injection molding and removing the outer skin; (b) forming a FIP polyurethane foam substrate between the substrate backing layer and the injection molded removable skin; (c) removing the injection molded removable skin from the FIP polyurethane foam substrate; and (d) bonding an outer wrap to an outer surface of the FIP polyurethane foam substrate. That is, the injection molded removable skin is reusable and may be used multiple times before a replacement injection molded removable skin is used to form additional instrument panels.

Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

Drawings

For a better understanding of the present disclosure, various forms thereof will now be described, by way of example, with reference to the accompanying drawings, in which:

FIG. 1 is a perspective view of a wrapping member formed according to a prior art method;

FIG. 1A is a cross-sectional view of section A-A of FIG. 1;

FIG. 2 is a schematic view of a process for forming a wrapped component according to the teachings of the present disclosure;

FIG. 3 is a schematic view of a foam-in-place (FIP) mold with an injection molded removable skin positioned within a cavity of the FIP mold in accordance with teachings of the present disclosure;

FIG. 4 is a schematic view of the FIP mold of FIG. 3 with a FIP die positioned within the cavity of the FIP mold in accordance with the teachings of the present disclosure;

fig. 5 is a schematic view of the FIP mold and FIP die of fig. 4 with the FIP substrate formed against the injection molded removable skin in accordance with the teachings of the present disclosure;

FIG. 6 is a perspective view of a wrapping member formed in accordance with the teachings of the present disclosure;

FIG. 6A is a cross-sectional view of section A-A in FIG. 6; and is

Fig. 7A-7F are schematic illustrations of steps for forming a wrapped component according to the teachings of the present disclosure.

The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

Detailed Description

The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

Referring to fig. 1, a wrapping member 100 formed by a prior art method is shown. The packaging component 100 has an outer surface 102 and an inner surface 104. As used herein, the phrase "packaging component" refers to an object that includes a substrate and an exterior material layer covering and attached to at least one surface of the substrate. The phrase "exterior surface" refers to the surface of the packaging component that faces toward the individual using the packaging component, while "interior surface" faces away from the individual using the packaging component. Non-limiting examples of wrap components include vehicle components such as Instrument Panels (IP), center consoles, door rollers, door armrests, and furniture components such as chair or sofa armrests, chair or sofa seats, chair or sofa leg supports, and the like. Thus, the outer surface 102 of the wrapping member 100 may be a surface of the vehicle IP, center console, door armrest, or the like that faces toward the individual seated in the vehicle, while the inner surface 104 may be a surface that faces away from the individual seated in the vehicle.

The packaging component 100 may include a plurality of layers located between an outer surface 102 and an inner surface 104 as schematically depicted in fig. 1A. For example, the wrapped component 100 may include an outer wrap layer 112, a separation layer 114 adjacent to and bonded to the outer wrap layer 112, a dummy layer 116 adjacent to and bonded to the separation layer 114, a FIP substrate 118 adjacent to and bonded to the dummy layer 116, and a substrate backing layer 122 adjacent to and bonded to the FIP substrate 118. As used herein, the term "wrap" or "wrap layer" refers to a layer or sheet of material that is bonded to a surface, and the phrase "outer layer" or "outer wrap layer" refers to a layer or sheet of material that is the outermost layer of a wrap component described herein. The process for manufacturing such a packaging component 100 may generally include: the dummy layer 116 is positioned within a mold cavity of a FIP mold, and then the FIP die with the substrate backing layer 122 attached is positioned within the mold cavity such that the substrate backing layer 122 is spaced apart from the dummy layer 116 with a gap therebetween. The gap is filled with foam using a FIP process, thereby forming a pre-form (not shown) comprising a FIP substrate 118, the FIP substrate 118 bonded between and to both the dummy layer 116 and the substrate backing layer 122. The pre-form is typically removed from the FIP mold and the spacer layer 114 and outer wrap 112 are attached to the dummy layer 116 to form the wrapped component 100.

Referring now to fig. 2, a schematic diagram of a process 20 for forming a wrapped component is shown in accordance with the teachings of the present disclosure. Process 20 generally includes using an injection molded skin that is removable from the FIP foam substrate (also referred to herein as an "injection molded removable skin") and reusable in the formation of additional wrapped components. Process 20 includes positioning an injection molded removable skin within a FIP mold at step 22 and forming a FIP foam substrate against the injection molded removable skin at step 24 to provide a preform that wraps the part. The injection molded removable skin may not be flame treated prior to being positioned within the FIP mold at step 22 and forming the FIP foam substrate against the injection molded removable skin. That is, if the injection molded removable skin is flame treated prior to forming the FIP foam substrate, the injection molded removable skin may adhere to the FIP foam substrate, making removal therefrom difficult and/or may tear or tear when removed therefrom. Thus, if the injection-molded removable skin is not flame treated prior to being positioned in the FIP mold, it may be more easily removed from the FIP foam substrate. As used herein, the phrases "flame treated", "flame treatment", "flame treating" and "flame treating" refer to the application of a gas flame to a surface of a material to improve the adhesion of the surface to another surface.

In some aspects of the present disclosure, the pre-form is formed by bonding a FIP foam substrate between and with an injection molded removable skin and a substrate backing layer attached to the FIP die. The injection molded removable skin is separated (removed) from the FIP foam substrate at step 26 and reused at step 27 to form additional FIP substrates at steps 22 and 24. In other aspects of the disclosure, the pre-form is removed from the FIP mold, and then the injection molded removable skin is separated (removed) from the FIP foam substrate at step 26 and reused at step 27 to form additional FIP substrates at steps 22 and 24.

The injection molded removable cover can be reused more than 10 times. For example, the injection molded removable cover may be reused more than 20 times, 30 times, 40 times, 50 times, or more than 60 times to form additional FIP substrates in steps 22 and 24. That is, the injection molded removable cover may be reused 10 to 20 times, 20 to 30 times, 30 to 40 times, 40 to 50 times, 50 to 60 times, or more than 60 times to form additional preforms at steps 22 and 24. In one form of the present disclosure, at step 28, a spacer layer is bonded to the FIP foam substrate and an outer layer is bonded to the spacer layer. In another form of the present disclosure, at step 29, the outer wrap is bonded directly to the FIP foam substrate, i.e., without bonding a spacer layer between and with the FIP foam substrate and the outer wrap.

Referring now to fig. 3, a schematic view of a FIP mold 30 having a mold cavity 34 is shown. The FIP mold 30 may include an optional heater element 32 that provides heat during the FIP process. The injection molded removable skin 210 may be positioned within the mold cavity 34 (step 22 of process 20). In some aspects of the present disclosure, the injection molded removable skin 210 may be held within the mold cavity 34 using a vacuum. That is, during the FIP process, the injection molded removable skin 210 is held against the walls and surfaces (not labeled) of the mold cavity 34 by vacuum (suction) of the walls (not labeled) of the FIP mold 30. The injection molded removable skin 210 may be formed of a thermoplastic elastomer (TPE) and may have a thickness between about 0.5 millimeters (mm) and about 20.0 mm. Non-limiting examples of TPEs include thermoplastic vulcanizates (TPVs), thermoplastic olefins (TPOs), Thermoplastic Polyolefins (TPOs), etc., which can be separated from the FIP foam substrate without tearing the injection molded removable skin 210 or the FIP foam substrate. Additionally, the injection molded removable skin 210 may not be flame treated (i.e., not subjected to flame treatment). In some aspects, the injection molded removable skin 210 may have a thickness between about 0.5mm and about 10.0 mm. For example, the injection molded removable skin 210 may have a thickness between about 0.5mm and about 1.0mm, between about 1.0mm and about 1.5mm, between about 1.5mm and about 2.0mm, between about 2.0mm and about 3.0mm, between about 3.0mm and about 4.0mm, between about 4.0mm and about 5.0mm, between about 5.0mm and about 6.0mm, between about 6.0mm and about 7.0mm, between about 7.0mm and about 8.0mm, between about 8.0mm and about 9.0mm, or between about 9.0mm and about 10.0 mm.

Referring now to fig. 4, a schematic view of the FIP mold 30 is shown with the FIP punch 36 positioned within the mold cavity 34. In some aspects of the present disclosure, substrate backing layer 220 is removably attached to a wall (not labeled) of FIP die 36. Similar to injection molded removable skin 210 being removably attached to the walls of mold cavity 34, substrate backing layer 220 may be removably attached to the walls of FIP die 36 using a vacuum. In other aspects of the disclosure, the substrate backing is not removably attached to a wall (not labeled) of FIP die 36 and a FIP foam substrate is formed between FIP die 36 and injection molded removable skin 210. In such an aspect, the walls of the FIP die may include a release agent that causes the FIP foam substrate to not adhere or stick to the walls of the FIP die after the preform (not labeled in fig. 4) has been formed and the FIP die 36 is removed from the mold cavity 34.

FIP die 36, with or without substrate backing layer 220, may have a shape that is complementary to the shape of FIP mold 30 such that the walls (not labeled) of FIP die 36 are spaced apart from injection molded removable skin 210 positioned within mold cavity 34. That is, a gap 'G' may be provided between the injection molded removable skin 210 and the substrate backing layer 220 (and the wall of the FIP die 36), as schematically depicted in fig. 4. It should be understood that gap G allows foam to be disposed (e.g., inserted and formed) between injection molded removable skin 210 and substrate backing layer 220 (and the walls of FIP die 36). That is, gap G allows for the formation of FIP foam substrate 230 and provides a pre-form 200p including injection molded removable skin 210, substrate backing layer 220, and FIP foam substrate 230 as schematically depicted in fig. 5.

Referring now to fig. 6 and 6A, a perspective view of preform 220p after removal from FIP mold 30 is schematically depicted in fig. 6, while a cross-sectional view of section a-a in fig. 6 is schematically depicted in fig. 6A. Pre-form 200p includes an outer surface 202 and an inner surface 204. Extending between the outer surface 202 and the inner surface 204 are an injection molded removable skin 210, a substrate backing layer 220, and a FIP foam substrate 230 positioned between and bonded to the injection molded removable skin 210 and the substrate backing layer 220.

Although fig. 6A only schematically depicts three layers (i.e., injection molded removable skin 210, substrate backing layer 220, and FIP foam substrate 230), it should be understood that, in some aspects of the present disclosure, additional layers may be included between outer surface 202 and inner surface 204 of pre-form 220 p. Non-limiting examples of additional layers include adhesive layers, filler layers, support layers, etc. between injection molded removable skin 210 and FIP foam base plate 230 and/or between base plate backing layer 220 and FIP foam base plate 230.

Referring now to fig. 7A-7F, a series of steps that may be included in forming the wrapping member 200 from the pre-form 200p is schematically depicted. In particular, a pre-form 200p formed during step 24 (fig. 2) and including an injection molded removable skin 210, a substrate backing layer 220, and a FIP foam substrate 230 positioned between and bonded to the injection molded removable skin 210 and the substrate backing 220 is schematically depicted in fig. 7A. Removal of the injection molded removable skin 210 is schematically depicted in fig. 7B at step 26 (fig. 2), while removal of the injection molded removable skin 210 is schematically depicted in fig. 7C to form an outer surface 232 on the FIP foam substrate 230. It should be understood that the surface (not labeled) of the injection molded removable skin 210 schematically depicted in fig. 7B that is in contact with the FIP foam substrate 230 may be free of flame treatment, thereby assisting or allowing removal of the injection molded removable skin 210 from the FIP foam substrate 230 without tearing or tearing the injection molded removable skin 210 and/or the FIP foam substrate 230. That is, flame treating the surface (not labeled) of the injection-molded removable outer skin 210 contacting the FIP foam substrate 230 once the FIP foam substrate 230 is formed may prevent the injection-molded removable outer skin 210 from being removed from the FIP foam substrate 230 without tearing or tearing.

Referring now to fig. 7D-7E, in some aspects of the present disclosure, a separation layer 240 is bonded to the outer surface 232, as schematically depicted in fig. 7D, and an outer wrap 250 is disposed over the separation layer 240 to form the wrapped component 200, as schematically depicted in fig. 7E. In one aspect of the present disclosure, the separation layer 240 is attached directly to the outer surface 232 of the FIP foam substrate 230, for example with an adhesive (not shown), and the outer wrap 250 is attached directly to the outer surface of the separation layer 240 (+ Y direction, not labeled), for example with an adhesive (not shown). Although not shown in fig. 7E, it is understood that additional layers as described above may be disposed between substrate backing 220 and FIP foam substrate 230, between FIP foam substrate 230 and spacer layer 240, and/or between spacer layer 240 and outer wrap 250.

Referring now specifically to fig. 7F, in other aspects of the present disclosure, an outer wrap 250 is bonded to the outer surface 232 without a separation layer 240 therebetween to form the wrapped component 200'. For example, as schematically depicted in fig. 1A, a separation layer 240 may be required to impart a "soft" feel to the wrapped component when skin 116 is held on substrate 118. However, when injection molding the removable skin 210 to form the pre-form 200p and then removed as schematically depicted in fig. 7B-7C, the FIP foam substrate 230 itself may provide a soft feel such that the spacer layer 240 is not required. Thus, the outer wrap 250 may be attached to the outer surface 232 of the FIP foam substrate 230 to form the wrapped component 200' without the need for a spacer layer 240 positioned therebetween. Although not shown in fig. 7F, it is understood that additional layers may be disposed between the substrate backing 220 and the FIP foam substrate 230 and/or between the FIP foam substrate 230 and the outer wrap 250. One non-limiting example of an additional layer is an adhesive layer. It should also be appreciated that forming wrap component 200 'without spacer layer 240 reduces the weight and cost of wrap component 200'.

It should be appreciated in light of the present disclosure that a method for forming a wrapped component without a dummy skin is provided. The method provides and uses an injection molded removable skin to form a wrapped part pre-form comprising a substrate backing layer, a FIP foam substrate, and an injection molded skin. The injection molded skin is removable, i.e. it is removed from the wrapping member pre-form and reused to form a plurality of wrapping members. The injection molded skin may be formed with an injection molding machine with a cycle time of less than about 120 seconds, such as less than about 60 seconds, to be replaced by a replacement injection molded skin in a timely and cost effective manner. Additionally, the injection molded removable skins disclosed herein can be manufactured using injection molding equipment already present within the wrapped component manufacturing facility such that no special equipment or materials may be required to form the replacement injection molded skin.

Unless expressly stated otherwise, all numbers expressing mechanical/thermal properties, compositional percentages, dimensions, and/or tolerances, or other characteristics, are to be understood as being modified by the word "about" or "approximately" in describing the scope of this disclosure. Additionally, the term "about" refers to experimental or measurement error/uncertainty of the measurements disclosed herein.

The description of the disclosure is merely exemplary in nature and, thus, variations that do not depart from the gist of the disclosure are intended to be within the scope of the disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure.

According to the invention, a method of forming a wrapped component comprises: positioning an injection molded skin in a foam-in-place (FIP) mold; forming a FIP foam substrate against the injection molded skin; removing the injection molded skin from the FIP foam substrate; and bonding an outer wrap to the FIP foam substrate to form a wrapped component, wherein the injection molded skin is subsequently used to form another wrapped component.

According to one embodiment, the injection molded skin comprises an injection molded polyolefin skin formed of a thermoplastic elastomer (TPE).

According to one embodiment, the TPE comprises thermoplastic vulcanizate (TPV).

According to one embodiment, the injection molded skin comprises a thickness between about 0.5mm and about 1.5 mm.

According to one embodiment, the FIP foam substrate comprises a FIP polyurethane foam substrate having a thickness between about 2.0mm and about 20.0 mm.

According to one embodiment, the outer wrap comprises a leather wrap.

According to one embodiment, the outer wrap comprises an artificial leather wrap.

According to one embodiment, the above invention is further characterized in that the replacement injection molded skin is formed after using the injection molded skin a predetermined number of times.

According to one embodiment, the above invention is further characterized by bonding a spacer layer between and to the FIP foam substrate and the outer wrap.

According to the present invention, a method of forming a plurality of instrument panels includes the steps of: positioning an injection molded removable skin formed from a polyolefin polymer in a foam-in-place (FIP) mold; forming a FIP polyurethane foam substrate between a substrate backing layer and the injection molded removable skin; removing the injection molded removable skin from the FIP polyurethane foam substrate and forming an outer surface on the FIP polyurethane foam substrate; bonding an outer wrap to the outer surface of the FIP polyurethane foam substrate to form an instrument panel; and repeating steps a-d using the same injection molded removable skin to form additional instrument panels.

According to one embodiment, the above invention is further characterized by forming a replacement injection molded removable skin after using said injection molded skin a predetermined number of times.

According to one embodiment, the replacement injection molded removable skin is formed with a cycle time of less than about 120 seconds.

According to one embodiment, the injection molded removable skin is formed of a thermoplastic elastomer (TPE).

According to one embodiment, the TPE is a thermoplastic vulcanizate (TPV).

According to one embodiment, the injection molded removable skin comprises a thickness between about 0.5mm and about 1.5 mm.

According to one embodiment, the FIP polyurethane foam substrate includes a thickness between about 2.0mm and about 20.0 mm.

According to one embodiment, the outer wrap comprises a leather wrap.

According to one embodiment, the outer wrap comprises an artificial leather wrap.

According to one embodiment, step d further comprises: bonding a separation layer to the outer surface of the FIP polyurethane foam substrate and bonding the outer wrap to the separation layer to form the instrument panel such that the outer wrap is bonded to the outer surface of the FIP polyurethane foam substrate through the separation layer.

According to the present invention, a method of forming a plurality of instrument panels having an exterior leather or synthetic leather surface, the method comprising the steps of: positioning an injection molded removable skin comprising a polyolefin polymer and a substrate backing layer in a foam-in-place (FIP) mold, wherein the injection molded removable skin is spaced apart from the substrate backing layer by a distance between about 2.0mm and about 20.0 mm; forming a FIP polyurethane foam substrate between the substrate backing layer and the injection molded removable skin; removing the injection molded removable skin from the FIP polyurethane foam substrate, wherein removing the injection molded removable skin forms an outer surface on the FIP polyurethane foam substrate; bonding an outer wrap to the outer surface of the FIP polyurethane foam substrate to form an instrument panel; and repeating steps a-d using the same injection molded removable skin as in step a to form at least 10 additional instrument panels.