Automotive interior trim assembly and pad insertion

Abstract

A trim assembly comprises a substrate member including a moveable panel integrally formed in the substrate and moveable between an open and closed position. A flexible skin overlies at least a portion of the substrate member and is integrally coupled to the substrate. The substrate and flexible skin are configured to define a cavity having an opening. The cavity opening is accessible when the moveable panel is in the open position. A resilient foam pad is positioned within the cavity to provide a soft feel to the trim assembly. The foam pad is inserted into the cavity using a tool that pulls a vacuum and compresses the foam pad. The foam pad is inserted into the cavity and the vacuum is released thereby expanding the foam pad to fill the cavity. The tool is removed and the moveable panel is moved to and secured in the closed position.

1 . A method of inserting a resilient foam pad within a cavity of an automotive trim assembly using an insertion tool including a surface for supporting the foam pad, the surface having a plurality of apertures therein for pulling a vacuum, the method comprising: 
 placing the foam pad on the surface of the insertion tool;    pulling a vacuum on the foam pad through the plurality of apertures;    compressing the foam pad using the vacuum;    inserting the insertion tool and foam pad through an opening in the cavity while the foam pad is compressed;    releasing the vacuum when the foam pad is positioned in the cavity;    expanding the foam pad by releasing the vacuum; and    removing the insertion tool from the cavity.    
     
     
         2 . The method of  claim 1  further comprising: 
 placing a moveable panel over the opening of the cavity; and    securing the moveable panel in a closed position.    
     
     
         3 . The method of  claim 2  wherein placing a moveable panel over the cavity opening comprises pivoting the moveable panel over the opening of the cavity.  
     
     
         4 . A method of forming an automotive interior trim assembly comprising: 
 forming a substrate member comprising at least part of a structural support of the trim assembly and including a moveable panel integrally formed in said substrate, said panel moveable between an open and closed position.