Method and apparatus for composite thermoplastic arm rest assembly

Abstract

An arm rest assembly that includes a thermoplastic arm rest body that defines an internal cavity and a support structure disposed within the internal cavity. The support structure is chemically compatible with the thermoplastic arm rest body such that a homogeneous chemical bond is formed between the support structure and the thermoplastic arm rest body. An arm rest cover is coupled to the arm rest body such that the internal cavity is enclosed by the arm rest body and the arm rest cover

What is claimed is: 
     
         1 . A method of forming a thermoplastic arm rest assembly, the method comprising:
 forming a support structure;   arranging the support structure in a mold;   molding a thermoplastic arm rest body around the support structure;   creating a homogeneous chemical bond between the support structure and the thermoplastic arm rest body; and   coupling an arm rest cover to the thermoplastic arm rest body.   
     
     
         2 . The method of  claim 1 , wherein the molding comprises at least partially encapsulating the support structure in the thermoplastic arm rest body. 
     
     
         3 . The method of  claim 2 , wherein the molding comprising completely encapsulating the support structure in the thermoplastic arm rest body. 
     
     
         4 . The method of  claim 1 , comprising forming a plurality of apertures in the support structure. 
     
     
         5 . The method of  claim 4 , wherein the plurality of apertures facilitate formation of a homogeneous chemical bond between the support structure and the thermoplastic arm rest body. 
     
     
         6 . The method of  claim 1 , comprising forming a homogeneous chemical bond between the support structure and the thermoplastic arm rest body. 
     
     
         7 . The method of  claim 1 , wherein the coupling comprises concealing the support structure. 
     
     
         8 . The method of  claim 1 , wherein the arranging comprises arranging the support structure with an integrated thermoplastic positioning system. 
     
     
         9 . The method of  claim 1 , comprising forming a pivot in the arm rest body. 
     
     
         10 . The method of  claim 1 , wherein the support structure comprises a thermoplastic laminate having a plurality of reinforcing fibers arranged therein. 
     
     
         11 . The method of  claim 10 , wherein the composite thermoplastic laminate comprises a unidirectional weave of reinforcing fibers. 
     
     
         12 . The method of  claim 10 , wherein the plurality of reinforcing fibers are chopped carbon fibers. 
     
     
         13 . The method of  claim 1 , wherein the support structure comprises a plurality of longitudinal ribs that extend generally parallel to the arm rest body. 
     
     
         14 . The method of  claim 13 , wherein the support structure comprises a plurality of lateral ribs that extend perpendicular to the longitudinal ribs.