CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of priority of US provisional application

61736235 filed December 12, 2012 and US provisional application 61879493 filed September 18, 2013, the entire contents of which are incorporated herein by reference.

FIELD OF THE INVENTION

[0002] The present invention relates generally to a vehicle interior component formed by depositing a metal coating onto a substrate or core material.

BACKGROUND OF THE INVENTION

[0003] Vehicle seating typically includes a seat bottom and a seat back to support a driver or passenger. In certain seating configurations, both the seat bottom and seat back include a rigid chassis, cushions, and a fabric covering. The cushions are coupled to the rigid chassis, and the fabric covering is disposed about the assembly. The rigid chassis of the seat bottom serves to support the weight (i.e., vertical load) of the passenger, and couples the seat to a floor of the vehicle. In certain configurations, the seat bottom chassis includes substantially horizontal surfaces for mounting to a seating track, and substantially vertical surfaces for securing the seat back chassis.

[0004] Certain seat bottom chassis and seat back chassis are constructed from stamped components. For example, a flat sheet of metal (e.g., steel, aluminum, etc.) may pass through a series of dies to form the sheet into a chassis component having a desired shape. Multiple chassis components may then be coupled to one another (e.g., via welding, bolting, bonding etc.) to form a seat bottom/seat back chassis. Unfortunately, the process of forming each component within a respective series of dies and then coupling the components to one another may significantly increase the duration and costs associated with forming the seat bottom/seat back chassis. In addition, the depth of certain features of the chassis may be limited by the maximum draw depth of the metal sheet. Accordingly, the chassis may be formed into a less desirable shape and/or more expensive techniques (e.g., welding additional components to the chassis) may be utilized to establish a feature having the desired depth. As a result, the duration and costs associated with forming the seat bottom/seat back chassis may be further increased.

[0005] Typically, automotive seat tracks may be made of high-strength steel, aluminum, or a high strength composite material. Steel may be used due to its strength and hardness, but it adds significant weight to the vehicle. The added weight may reduce the fuel economy of the vehicle. The aluminum seat tracks, on the other hand, may provide a lower weight for the fuel economy, but aluminum is more expensive than steel and aluminum tracks do not provide sufficient hardness and durability that steel may provide. For example, rolling media, such as ball bearings within the seat track assembly, may deform the aluminum seat track surfaces, causing undesired effects like poor feel for the user (as a result of surface deformation), brinelling, and increased sliding friction. In order for an aluminum seat track to provide sufficient strength and stiffness to support the vehicle seat and the occupant, the aluminum seat track must be larger than a steel seat track and therefore difficult to fit within the space requirements of the vehicle.

SUMMARY OF THE INVENTION [0006] The present invention relates to a vehicle interior component manufactured by a process including forming a substrate or core material having a desired shape of the vehicle interior component. The process also includes depositing a metal coating onto a first surface of the substrate to form the vehicle interior component. A portion of a strength of the vehicle interior component can be provided by the metal coating, and the metal coating does not need to extend to a second surface of the substrate.

[0007] The present invention also relates to a vehicle interior component manufactured by a process including forming a substrate having a desired shape of the vehicle interior component. The process also includes depositing a metal coating onto a surface of the substrate to form the vehicle interior component. The metal coating includes a first thickness layer and a second thickness layer, the first thickness is different than the second thickness, and the first and second thicknesses are selected based on an expected stress within the vehicle interior component.

[0008] The present invention further relates to a method of manufacturing a vehicle interior component including forming a polymeric substrate having a desired shape of the vehicle interior component. The desired shape and/or material properties of the substrate are selected based on an expected stress within the vehicle interior component. The method also includes depositing a metal coating onto the substrate to form the vehicle interior component. The metal coating is configured to reduce fatigue crack propagation through the polymeric substrate and/or to enhance impact resistance of the polymeric substrate.

[0009] The present invention is especially useful for forming the seat track of a seat adjusting mechanism. The seat adjusting mechanism adjusts the position of the seat in a motor vehicle, and it usually has rolling media which allows one seat track to slide or roll on another seat track. In a preferred embodiment of the present invention, an aluminum substrate is used for the seat track, and then a metal coating is plated onto the aluminum substrate, where the metal coating has a higher hardness and/or strength than the aluminum substrate. Preferable materials for the metal coating include nickel and iron, alloys of nickel and iron, and/or salts of nickel and iron. A plurality of metal coating layers can be applied to the substrate, preferably alternating between two different materials of the metal coating. The metal coating has a greater strength and/or hardness than the aluminum substrate, and the aluminum substrate is a lighter, less dense, material than the metal coatings. The lighter weight, lower density, of the substrate reduces the overall weight of the seat track, while the increased strength provided by the metal coating allows a reduction in size compared to an all aluminum seat track. The increased hardness of the metal coating also improves the operation and reliability of the seat adjusting mechanism.

[0010] The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] FIG. 1 is a perspective view of an exemplary vehicle that may include a vehicle interior component formed by depositing a metal coating onto a polymeric substrate;

[0012] FIG. 2 is a perspective view of an interior of the vehicle of FIG 1 ;

[0013] FIG. 3 is a perspective view of an exemplary vehicle seat that may include a chassis and a plated seat track formed by depositing a metal coating onto a substrate;

[0014] FIG. 4 is a process flow diagram of an embodiment of a method for forming a seat back chassis by depositing a metal coating onto a substrate;

[0015] FIG. 5 is a perspective view of a plated seat track of a vehicle seat according to one embodiment of the present invention;

[0016] FIG. 6 is a perspective, cross-sectional view of the plated seat track of FIG. 5;

[0017] FIG. 7 is a cross-sectional view of a portion of a plated seat track of a vehicle seat according to one embodiment of the present invention;

[0018] FIG. 8 is a perspective view of a plated seat track of a vehicle seat according to one embodiment of the present invention;

[0019] FIG. 9 is a side view of the plated seat track of FIG. 8;

[0020] FIG. 10 is a cross-sectional view of the plated seat track of FIG. 8;

[0021] FIG. 11 is a cross-sectional view of a plated seat track of a vehicle seat according to one embodiment of the present invention;

[0022] FIG. 12 is a cross-sectional view of the integrated gear box housing bracket of the plated seat track of FIG. 8;

[0023] FIG. 13 is a side view of the plated seat track of FIG. 12;

[0024] FIG. 14 is a top view of the plated seat track of FIG. 12;

[0025] FIG. 15 a cross-sectional view of the integrated pivot bracket of the plated seat track of FIG. 8;

[0026] FIG. 16 is a side view of the plated seat track of FIG. 15;

[0027] FIG. 17 is a flowchart of an embodiment of a method for forming a vehicle interior component by depositing a metal coating onto a polymeric substrate;

[0028] FIG. 18 is a process flow diagram of an embodiment of a method for forming a vehicle interior component by depositing a metal coating onto a polymeric substrate;

[0029] FIG. 19 is a detailed side view of the vehicle interior component of FIG. 18, taken within line 18-18; [0030] FIG. 20 is a perspective view of an embodiment of a vehicle interior component having a variable thickness polymeric substrate.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0031] Referring to the drawings in particular, FIG. 1 is a perspective view of an exemplary vehicle 10 that may include a vehicle interior component formed by depositing a metal coating onto a substrate or core material. The substrate/core material can be easier to manufacture and/or lower weight such as a polymeric, aluminum, plastic, or a composite material. As illustrated, the vehicle 10 includes an interior 12 having a seat 14, and a center console 16. In certain embodiments, the seat 14 may include a one-piece chassis (e.g., seat bottom chassis, seat back chassis, etc.) formed by depositing a metal coating onto a substrate. For example, the metal coating may provide increase the strength/structural rigidity of the chassis, thereby establishing a chassis configured to resist loading during normal vehicle operation and during high g-force events (e.g., an impact). In addition, the thickness of the metal coating, the shape of the substrate, and/or the material properties of the substrate may be particularly selected based on the expected stress within the chassis. As a result, a light-weight chassis having a desired shape and structural properties may be formed.

[0032] FIG. 2 is a perspective view of the interior 12 of the vehicle 10 of FIG. 1. As illustrated, the interior 12 includes a center console 16, an instrument panel 18, a door panel 20, sun visors 22, and an overhead console 24. As discussed in detail below, each vehicle interior component may include a substrate and a metal coating deposited onto the substrate. In certain embodiments, the substrate may form a show surface of the component, and the metal coating, which is positioned on a rear surface of the component, may provide additional

strength/structural rigidity to the component. For example, the door panel 20 may have a show surface formed by a polymeric substrate, and a rear surface formed by a metal coating deposited onto the polymeric substrate. The thickness of the metal coating, the shape of the polymeric substrate, and/or the material properties of the polymeric substrate may be particularly selected based on the expected stress within the door panel 20. Accordingly, a light-weight door panel having a desired shape and structural properties may be formed. While a door panel 20 formed by depositing a metal coating onto a polymeric substrate is described below, it should be appreciated that other components of the vehicle interior, such as the center console 16, the instrument panel 18, the sun visor 20, and the overhead console 24, may be formed by a similar process.

[0033] Furthermore, forming a chassis, a seat track, or other seat component by depositing a metal coating onto a substrate may substantially reduce seat construction costs, as compared to seat chassis or track that include multiple stamped components secured together to form a complete structure. For example, seat chassis having multiple stamped components of different shapes (e.g., brackets, cushion pan, etc.) may utilize separate dies, or separate series of dies, to stamp each component. As will be appreciated, construction cost may increase proportionally to the number of dies due to the expense associated with designing and building each die. In contrast, one embodiment of the present invention forms a chassis by depositing a metal coating onto a one-piece polymeric substrate. Because the polymeric substrate may be formed by a low-cost injection molding process, the costs associated with forming multiple metal-stamping dies may be substantially reduced or eliminated. In addition, because the entire seat chassis is formed as a single unit, labor and material costs associated with joining the individual components may be substantially reduced or eliminated. Moreover, the resultant one-piece seat chassis may be lighter than multi-component chassis because of the reduction in the number of connections (i.e., fewer weld joints, fewer bolted connections, etc.).

Consequently, the one-piece seat chassis may be both lighter and less expensive to produce than conventional chassis formed by coupling multiple stamped components to one another.

[0034] As discussed in detail below, the seat bottom chassis 30, the seat back chassis

32 and/or the seat track may be formed by depositing a metal coating onto a substrate. For example, a polymeric substrate having a desired shape of the chassis is formed (e.g., via an injection molding process). Next, a metal coating is deposited onto a surface of the polymeric substrate to form the chassis. In certain embodiments, a thickness of the metal coating within various regions of the chassis may be particularly selected based on the expected stress.

Accordingly, a chassis having a desired shape and material properties may be formed. In certain embodiments, the polymeric substrate may be removed from the metal coating to establish a substantially metallic chassis. In alternative embodiments, the polymeric substrate may remain coupled to the metal coating to enhance the strength of the chassis and/or to provide mounting surfaces for additional seating components (e.g., a reclining mechanism, headrest mounts, etc.). Mounting the additional seating components to the polymeric substrate may reduce noise and vibration during operation of the vehicle, as compared to mounting the components directly to a metal surface. [0035] FIG. 3 is a perspective view of a vehicle seat 14 that includes a chassis and/or a seat track 36 with mounting feet 38 formed by depositing a metal coating onto a substrate. As illustrated, the seat 14 includes a seat bottom 26 and a seat back 28. In the illustrated embodiment, the seat bottom 26 includes a one-piece seat bottom chassis 30, one or more cushions coupled to the chassis, and a fabric covering disposed about the assembly. In addition, the seat back 28 includes a one-piece seat back chassis 32, one or more cushions coupled to the chassis, and a fabric covering disposed about the assembly. Each one-piece seat chassis serves to support the weight of a passenger during normal vehicle operation and during high g-force events (e.g., rapid acceleration or deceleration, etc.). As discussed in detail below, the seat bottom chassis 30 also secures the seat 14 to a floor of the vehicle 10. A headrest 34 is coupled to the seat back 28 (e.g., via support tubes extending from the seat back chassis 32).

[0036] Because the metal portion of the chassis is formed by depositing a metal coating onto a substrate, such as a polymeric substrate, the process of stamping chassis components can be obviated, thereby reducing the duration and costs associated with forming a seat chassis. In addition, because the substrate may be coupled to the metal layer, the strength/structural rigidity of the seat chassis may be enhanced. Moreover, because the substrate may be molded into any suitable shape, the chassis may include features having a depth greater than the maximum draw depth of a stamped component. For example, the draw depth of a stamped component may be limited by the thickness and/or the material properties of the metal.

However, because the metal portion of the illustrated chassis is formed by depositing a metal coating onto a substrate, such as a polymeric substrate, the chassis may include features having depths greater than the maximum draw depth of a stamped component having an equal thickness and/or material properties.

[0037] As illustrated, the seat bottom chassis 30 is slidably coupled to the seat track 36.

The seat track 36, in turn, is secured to the floor of the vehicle 10 by the mounting feet 38. In certain configurations, the seat 14 may be configured to translate along the seat track 36 to adjust a longitudinal position of a driver or passenger. As will be appreciated, adjustment of the seating position may be either manual or assisted. For example, an electric motor may be configured to drive the seat 14 along the track 36 by a suitable mechanism such as a rack and pinion system.

[0038] FIG. 4 is a process flow diagram of an embodiment of a method for forming a seat back chassis by depositing a metal coating onto a polymeric substrate. First, as represented by step 40, a polymeric substrate 42 having a desired shape of the seat back chassis 32 is formed. For example, the polymeric substrate 42 may be formed by an injection molding process. Injection molding involves injecting a liquid polymer into a mold cavity having the shape of the chassis. After the liquid polymer cures and hardens into the polymeric substrate 42, the polymeric substrate 42 is removed from the mold cavity. It should be appreciated that alternative methods for fomiing the polymeric substrate may be employed in certain

embodiments. For example, the polymeric substrate may be machined from a larger block of material, or the polymeric substrate may be formed by a three-dimensional (3D) printer. The polymeric substrate may be formed from any suitable material (e.g., dependent upon the method used to form the substrate). For example, the polymeric substrate 42 may be formed from polypropylene, polyethylene, polycarbonate, or another suitable material.

[0039] In the illustrated embodiment, the polymeric substrate 42 includes a web 44, and two supports 46 positioned on opposite lateral sides of the web 44. The web 44 also includes an opening 48 configured to reduce the weight of the seat back chassis 32. Furthermore, the polymeric substrate 42 includes anchor points 50 for securing additional seating features (e.g., cushion support springs) to the chassis. In the present embodiment, the web 44, the supports 46, the opening 48, and the anchor points 50 are formed by an injection molding process. As will be appreciated, the polymeric substrate 42 may include additional features (e.g., flanges, stiffening ridges, etc.) to enhance the strength of the seat back chassis 32. In addition, as described in detail below, the shape and/or material properties of the polymeric substrate 42 may be particularly selected based on the expected stress within the seat back chassis 32.

[0040] Next, as represented by step 52, a metal coating 54 is deposited onto a surface of the polymeric substrate 42. In certain embodiments, the metal coating is applied using an electrodepositing technique in which the polymeric substrate is submerged in a solution containing two metal salts, such as nickel and iron. Applying a current of a first polarity (e.g., positive) to the polymeric substrate induces a layer of the first metal (e.g., iron) to be applied, and applying a current of a second polarity (e.g., negative) to the polymeric substrate induces a layer of the second metal (e.g., nickel) to be applied. Alternating between polarities at a desired interval produces the multilayered alloy coating 54 (e.g., alternating layers of iron and nickel) on the surface of the polymeric substrate 42. As illustrated, the alloy coating 54 matches the contours of the polymeric substrate 42. [0041] In the illustrated embodiment, a thickness of the metal coating 54 is particularly selected based on the expected stress within the seat back chassis 32. As illustrated, a first portion 56 of the coating 54 has a first thickness 58, and a second portion 60 of the coating 54 has a second thickness 62, greater than the first thickness 58. For example, the bending loads adjacent to the base of the seat back chassis 32 may be greater than the bending loads at the top of the chassis. Accordingly, a thicker layer of meal is applied adjacent to the base to enhance the structural integrity of the region that may experience a higher load. Because the thickness of the metal coating may be adjusted, a designer/engineer may have more control over the structural properties of the chassis, as compared to a chassis formed from stamped

components. [0042] In certain embodiments, the polymeric substrate 42 may be partially immersed in the solution so that only a part of the polymeric substrate (e.g., one surface) is coated with the metal coating 54. In other embodiments, the polymeric substrate 42 may be fully immersed for a first portion of the coating process, and partially immersed for a second portion of the coating process. Adjusting the immersion may establish the variation in coating thickness described above. As a result of the variable coating thickness, the strength, stiffness, hardness, and/or toughness of various regions of the seat back chassis 32 may be enhanced.

[0043] In certain embodiments, the seat back chassis 32 may include the polymeric substrate 42 and the metal coating 54. In such embodiments, the metal coating 54 may provide at least 10 percent, 20 percent, 30 percent, 40 percent, 50 percent, 60 percent, 70 percent, or more of the strength/structural rigidity of the chassis 32. By way of example, the metal coating 54 may provide about 10 percent to about 90 percent, about 20 percent to about 80 percent, or about 30 percent to about 70 percent of the strength/structural rigidity of the chassis 32.

[0044] In alternative embodiments, the polymeric substrate 42 is removed from the metal coating, as represented by step 64. Removing the polymeric substrate 42 leaves behind the metal coating 54, thereby establishing a substantially metallic seat back chassis 32. Various methods may be utilized to remove the polymeric substrate 42. For example, heat may be applied to melt the polymeric substrate 42, thereby leaving behind the metal coating 54. In other embodiments, the polymeric substrate 42 may be chemically etched away or physically milled from the metal coating 54. Forming the metal seat back chassis 32 in this manner may be significantly more cost effective than stamping multiple components and coupling the components to one another. In addition, a stronger and/or lighter seat back chassis 32 may be formed. While the process described above is employed to form a seat back chassis 32, it should be appreciated that the process may be utilized to form the seat bottom chassis 32 and/or any other suitable component within the vehicle interior, especially the seat tracks 36.

[0045] Referring to Figure 5, disclosed herein is a plated seat track, as shown according to exemplary embodiments. It has been detemiined that a seat track with a highly desirable balance of weight and strength can be obtained by fomiing the seat track by using a substrate and coating it with a structural plating material. [0046] The seat track may be used to control the positioning of a seat, such as a vehicle seat. More specifically, the seat track may control the positioning of the entire seat relative to a floor or a seat back relative to a seat base. The plated seat track may be used in a variety of applications, including automotive devices and is particularly useful within a seat track in any type of vehicle, such as a two door or four door automobile, a truck, a SUV, a van, a train, a boat, an airplane, or other suitable vehicular conveyance. The plated seat track is also useful in any non- vehicle application wherein it would be desired to have a material with high strength and hardness and low friction.

[0047] An embodiment of the present invention as a seat track is depicted in FIG. 3, in which a plated seat track 36 is affixed to the vehicle seat 22. The plated seat track 36 of the present invention may be particularly useful for moving the vehicle seat 22 relative to, for example, the floor of vehicle 10 while providing adequate strength, hardness, and durability and not adding significant weight to the vehicle 10. [0048] Referring to FIG. 5, there is shown the plated seat track 36 according to one embodiment of the present invention, which may include an upper rail 132, a lower rail 134, and ball bearings 136. The upper rail 132 may be movable along the lower rail 134 with the assistance of the ball bearings 136.

[0049] The upper rail 132 and the lower rail 134 may be constructed out of a substrate 140, coated with at least a layer of plating material 144. A variety of different methods may be used to coat the substrate 140 with the plating material 144, such as nano lamination, nanolayering, and/or electrodepositing. FIG. 6 shows a cross-sectional view of the plated seat track 36 of FIG. 5, in which the substrate 140 is coated with the plating material 144, forming the plated seat track 136. [0050] FIG. 7 shows a cross-sectional view of a portion of a plated seat track 36, in which the substrate 140 and the plating material 144 are distinctly shown. The plating material 144 is exaggerated and separated from the substrate 140 for purposes of depicting the separate layers. However, the plating material 144 may be a variety of thicknesses and may attach directly or indirectly to the substrate 140. [0051] The substrate 140 may be a lower weight material, such as aluminum, plastic, or a composite material. Alone, the substrate 140 may not provide sufficient strength or hardness to effectively function as a seat track while conforming to the size restraints within the vehicle 10. Additionally, the substrate 140 alone may not be durable and may wear out quickly. The plating material 144 on the surface of the substrate 140, however, increases the strength, stiffness, and surface hardness of the substrate 140, thereby obtaining at least an equivalent hardness and strength of a steel seat track, while minimizing the weight and size.

[0052] The plating material 144 may create a strong shell around the substrate 140, creating a composite hard and strong plated seat track 36. The plating material 144 may be a variety of different materials, wherein the plating material 144 is stronger and harder than the substrate 140. For example, alloys, like a nickel alloy, or specific salts, like nickel salt and/or iron salt, may be used as the plating material 144. With electrolytic plating or nano lamination, for example, alternating layers of metals (the plating material 144) may be plated onto the substrate 140. According to one exemplary embodiment of the present invention, alternating layers of nickel and iron may be applied to or electrodeposited onto an electrically conductive, zinc-plated, aluminum substrate 140 by means of electrolytic plating. Pre-treating the aluminum substrate 140 with zinc may prevent the aluminum from fomiing oxides during the electrolytic plating. The plating material 144 may create a thin, highly dense shell around the substrate 140. For example, the plating material may be around 0.1 millimeters thick.

[0053] With the combination of the substrate 140 and the plating material 144, the size, weight, and mass of the plated seat track 36 is minimized, while providing sufficient strength and surface hardness. For example, the ball bearings 136 will not cause brinelling or deform the surface of the plated seat track 36 as the occupant uses and adjusts the vehicle seat 14.

Additionally, since the substrate 140 is a lower weight material and may comprise the majority of the mass of the plated seat track 36, the overall weight of the plated seat track 36 is less than a steel seat track, which may improve the fuel economy of the vehicle 10 while maintaining sufficient strength and hardness. [0054] A variety of known techniques or processes may be used to construct the plated seat track 36. For example, Integran has developed a process in which a structural metal material is plated over plastic or aluminum to create a metal exoskeleton. More specifically, one process described by Integran may be found in US patent application US2012237789, hereby incorporated by reference. Alternatively, Modumetal of 1443 N. Northlake Way, Seattle, Wash. 98103, has developed a process in which alternating layers of nickel and iron may be electrodeposited onto electrically conductive aluminum to create a multilayered alloy. In one exemplary embodiment, the substrate 140 (such as aluminum) may be at least partially immersed into a "bath" or an electrodeposition solution containing a nickel salt and an iron salt. An electric current is repeatedly passed through the bath and the immersed section of the substrate 140. The electric current may alternatively be pulsed for predetermined durations between a first electrical current that is effective to electrodeposit nickel and a second electrical current that is effective to electrodeposit iron. This process creates a multilayered alloy (the plated seat track 36) with adjacent layers of nickel and iron (the plating material 144) on the immersed surface of the substrate 140. The substrate 140, now coated with the plating material 144, exhibits high strength and hardness and low friction. This process may also result in the plated seat track 36 with a greater resistance to corrosion, improved fatigue failure resistance, and a decreased risk of cracks and stress failure. The structural properties, such as strength, stiffness, hardness, and toughness, may be optimized by tailoring the plating material 144 layer thickness and interface properties. [0055] Referring now to FIGS. 8 and 9, there is shown the plated seat track 36 according to one embodiment. As shown in FIGS. 8 and 9, the substrate 140, and therefore the plated seat track 36, may be constructed into a variety of different and complex shapes and geometries that may not be possible with steel. Additionally, extra components may be integrated (by, for example, extruding or molding) onto the plated seat track 36, thereby combining multiple parts into one strong and durable part. The entire surface of the substrate 140 with extra integrated components may be coated with the plating material 144. This may reduce any friction between the parts that may have previously resulted in a traditional seat track with multiple separate parts. The number of assembly steps may also be reduced.

[0056] For example, as shown in FIGS. 8 and 9, there may be an integrated pivot bracket 156 and an integrated gear box housing/bracket 158 along the length of the plated seat track 36. These components may also be constructed out of the substrate 140 that is coated with the plating material 144. These components, with the plated seat track 36, may be constructed as one piece. For example, the pivot bracket 156 and the gear box housing/bracket 158 may be integrated with the upper rail 132 as one piece. [0057] Referring now to FIG. 10, there is shown a cross-sectional view of the plated seat track 36 with the upper rail 132, movable along the lower rail 134 of FIG. 8. Ball bearings 136 may aid the movement between the upper rail 132 and the lower rail 134. The plated seat track 36 may at least be partially constructed out of the substrate 140 that is coated in the plating material 144. [0058] Referring now to FIG. 11, there is shown a cross-section of one embodiment of the plated seat track 36. The plated seat track 36 may be constructed in a variety of different and complex configurations, according to the desired use. For example, the plated seat track 36 may include an inner rail 152 that may move along an outer rail 154. [0059] Referring now to FIGS. 12-14, the integrated gear box housing/bracket 158 of the plated seat track 36 of FIG. 8 integrated with the upper rail 132 is shown. FIG. 12 shows a cross-sectional view of the integrated gear box housing/bracket 158, FIG. 13 shows a side view of the integrated gear box housing/bracket 158, and FIG. 14 shows a top view of the integrated gear box housing/bracket 158. Alternatively or additionally, other components with any shape or size may be integrated anywhere along the plated seat track 36 according to the present invention.

[0060] Referring now to FIGS. 15 and 16, there is shown a cross-sectional view and a side view of the integrated pivot bracket of the plated seat track 36 of FIG. 8. As shown in FIG. 15, both the pivot bracket 156 and the gear box housing/bracket 158 may be integrated with the upper rail 132.

[0061] FIG. 17 is a flowchart of an embodiment of a method 66 for fomiing a vehicle interior component by depositing a metal coating onto a substrate. First, as represented by block 68, a preferably polymeric substrate having a desired shape of a vehicle interior component is formed. The substrate however may be formed of other materials such as, but not limited to. a lightweight metal, plastic or composite For example, the substrate may be formed by an injection molding process. Injection molding involves injecting a liquid, such as a polymer or aluminum, into a mold cavity having the desired shape of the vehicle interior component. After the liquid cures and/or hardens into the substrate, the substrate is removed from the mold cavity. It should be appreciated that alternative methods for fomiing the substrate may be employed in certain embodiments. For example, the substrate may be machined from a larger block of material, or the substrate may be formed by a

three-dimensional (3D) printer. [0062] After the substrate is formed, a metal coating is deposited onto a surface of the substrate to form the vehicle interior component, as represented by bock 70. For example, in certain embodiments, the metal coating may include a first thickness and a second thickness different than the first thickness. In such embodiments, the first and second thicknesses may be selected based on an expected stress within the vehicle interior component, thereby establishing a component having desired structural properties. In addition, the metal coating may be applied using an electrodepositing technique in which the substrate is submerged in a solution containing two metal salts, such as nickel and iron. Applying a current of a first polarity (e.g., positive) to the substrate induces a layer of the first metal (e.g., iron) to be applied, and applying a current of a second polarity (e.g., negative) to the polymeric substrate induces a layer of the second metal (e.g., nickel) to be applied. Alternating between polarities at a desired interval produces the multilayered alloy coating (e.g., alternating layers of iron and nickel) on the surface of the substrate. Depositing the metals in alternating layers may increase resistance to corrosion and/or increase the strength of the metal coating. [0063] Varying the amplitude and/or the duration of the electric current establishes corresponding variations in the thickness of each metal layer. Adjusting the thickness of each layer may vary the strength, stiffness, hardness, and/or toughness of the metal coating and/or the vehicle interior component. The thickness of each layer may range between a fraction of a nanometer to a few microns. For example, the thickness of each layer may range from about 0.1 nanometers to about 10 microns, from about 0.3 nanometers to about 1 micron, from about 0.5 nanometers to about 100 nanometers, or from about 1 nanometer to about 10 nanometers. By way of further example, the thickness of each layer may be less than about 1 nanometer, less than about 10 nanometers, less than about 100 nanometers, or less than about 1 micron.

[0064] In certain embodiments, the substrate is removed from the metal coating, especially when the substrate is a polymeric, as represented by block 72. As previously discussed, the removal may be preformed by any suitable chemical or physical process (e.g., chemical etching, application of heat, etc.). Removing the substrate may be desirable if an all-metal vehicle interior component is desired for a particular application (e.g., seat bottom/back chassis). Fomiing the vehicle interior component in this manner may substantially reduce the duration and/or costs associated with the manufacturing process (e.g., as compared to forming the component by coupling multiple stamped parts to one another).

[0065] FIG. 18 is a process flow diagram of an embodiment of a method for forming a vehicle interior component by depositing a metal coating onto a substrate. First, as represented by step 74, a substrate 76 having a desired shape of a vehicle interior component, such as the illustrated door panel 20, is formed. In the illustrated embodiment, the substrate 76 includes an armrest 78, an opening 80 for a speaker, and an opening 82 for placement of a door handle/locking mechanism. As previously discussed, the substrate 76 may be formed by a variety of methods, including injection molding. In the illustrated embodiment, the substrate 76 includes a first surface 84 and a second surface 86. As discussed in detail below, a metal coating is applied to the first surface 84, and the second surface 86 is configured to face an interior of the vehicle. In certain embodiments, the second surface 86 may form a show surface of the door panel 20. Accordingly, the substrate 76 may include certain features (e.g., colors, textures, etc.) to enhance the appearance of the door panel.

[0066] Next, as represented by step 88, a metal coating 90 is deposited onto the first surface 84 of the substrate 76 to form the vehicle interior component. The metal coating is applied one layer at a time, as described above, by at least partially immersing the substrate 76 into a solution of metallic salts, and applying an electric current that alternates polarity. In the illustrate embodiment, the metal coating 90 is only applied to the first surface 84. That is, the metal coating 90 does not extend to the second surface 86 of the substrate 76. For example, only the first side 84 of the substrate 76 may be immersed into the metal salt solution.

Alternatively, the second side 86 may be coated with a material that blocks adhesion of the metal coating to the substrate 76. Once the vehicle interior component is formed, the features present in the template/substrate 76, such as the armrest 78, the speaker opening 80, and the handle opening 82, form corresponding elements in the vehicle interior component. As previously discussed, the metal coating 90 provides a portion (e.g., preferably 50 percent) of the strength/structural rigidity of the vehicle interior component.

[0067] In certain embodiments, additional layers of material (e.g., foam, fabric cover stock, etc.) may be applied to the second surface 86 to form the show surface. Alternatively, as previously discussed, the second surface 86 of the substrate 76 may form the show surface of the vehicle interior component. In further embodiments, the metal coating 90 may be deposited on the second side 86 of the substrate 76 to form a metallic show surface. While the process described above is employed to form a door panel 20, it should be appreciated that the process may be employed to form other vehicle interior components, such as the sun visor 20, the center console 16, and/or the instrument panel 18.

[0068] FIG. 19 is a detailed side view of the vehicle interior component of FIG. 18, taken within line 18-18. As illustrated, the metal coating 90 is deposited onto the first surface 84 of the substrate 76. As previously discussed, the metal coating includes alternating layers of a first metal 92 (e.g., iron) and a second metal 94 (e.g., nickel). In certain embodiments, the metal layers 92 and 94 are successively deposited via electrodeposition. The metal coating 90 enhances the strength of the vehicle interior component, thereby establishing a component having the desired shape and the desired structural properties.

[0069] While the illustrated metal coating 90 includes 10 layers, it should be appreciated that alternative embodiments may include significantly more layers. As previously discussed, the thickness of each layer may be between about 0.1 nanometers to about 10 microns. By way of example, if the thickness of each layer is about 1 nanometer and the thickness 96 of the metal coating is about 1 mm, the metal coating has about 1,000,000 layers. However, it should be appreciated that the thickness of each layer and/or the thickness 96 of the metal coating may vary in alternative embodiments. For example, in certain embodiments, the thickness 96 of the metal coating 90 may be less than 10 microns, 100 microns, 1 mm, or 10 mm. By way of example, certain stamped components may be formed from sheet metal having a thickness of about 1 mm. Because the layered metal coating may be significantly stronger than the sheet metal, the thickness of the metal coating may be less than 1 mm, while providing the desired strength. In addition, the substrate may provide additional support to the metal coating, thereby facilitating a further reduction in the metal coating thickness.

[0070] FIG. 20 is a perspective view of an embodiment of a vehicle interior component having a variable thickness substrate. In the illustrated embodiment, the vehicle interior component, such as the illustrated mounting foot 38, includes openings 98 for mounting the component to the floor of the vehicle and to the seat track 36. As best seen in the cutout section 100, the vehicle interior component includes a preferably polymeric substrate 102 having a desired shape of the vehicle interior component, and a metal coating 104 deposited onto the substrate 102 to form the vehicle interior component. In the illustrated embodiment, the shape and/or the material properties of the substrate 102 may be particularly selected based on the expected stress within the vehicle interior component. For example, the substrate 102 may be thicker in regions of higher stress and thinner in regions of lower stress. Accordingly, the thickness of the substrate 102 may vary throughout the vehicle interior component, as illustrated. In addition, the composition of the substrate 102 may vary based on the expected stress. Furthermore, reinforcement material 106 may be disposed within the substrate 102 to enhance the strength of the substrate. By way of example, glass fibers, polymeric fibers, carbon fibers, ceramic fibers, and/or metallic fibers may be disposed within the substrate 102, at least within regions of higher expected stress. By adjusting the shape and/or the material properties of the substrate 102, a vehicle interior component having a desired shape and a desired strength may be formed. In addition, the metal coating 102 may enhance the strength of the substrate 102, reduce fatigue crack prorogation through the substrate, and/or enhance impact resistance of the substrate. While the vehicle interior component described above is a mounting foot 38, it should be appreciated that the process for fomiing the vehicle interior component may be applied to other vehicle interior components, such as the sun visor 20, the center console 16, and/or the instrument panel 18. [0071] The embodiments disclosed herein create vehicle components that provide sufficient hardness and strength while limiting the weight, size, and mass. Besides those embodiments depicted in the figures and described in the above description, other embodiments of the present invention are also contemplated. For example, any single feature of one embodiment of the present invention may be used in any other embodiment of the present invention.

[0072] While only certain features and embodiments of the invention have been illustrated and described, many modifications and changes may occur to those skilled in the art (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters (e.g., temperatures, pressures, etc.), mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention. Furthermore, in an effort to provide a concise description of the exemplary embodiments, all features of an actual implementation may not have been described (i.e., those unrelated to the presently contemplated best mode of carrying out the invention, or those unrelated to enabling the claimed invention). It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation specific decisions may be made. Such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure, without undue experimentation.

[0073] While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.