Vertical Trim Panel with Integrated Stitching

• US 20080157432A1
• Filed: 12/02/2005
• Published: 07/03/2008
• Est. Priority Date: 12/03/2004
• Status: Active Grant

• Current Assignee: Yanfeng Czechia Automotive Interior Systems s.r.o.
• Original Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Inventors: Boyer, Stan P.
• Granted Patent: US 8,071,002 B2
• Time in Patent Office: Days
• US Class Current: 264/257
• CPC Class Codes: B29C 2045/14909 the edge of the sheet-like insert being hidden, e.g. in a groove or protruding into the injected material
• CPC Class Codes: B29C 45/14811 Multilayered articles B29C45/14827 takes precedence
• CPC Class Codes: B29K 2715/003 Cellular or porous
• CPC Class Codes: B29L 2031/3005 Body finishings
• CPC Class Codes: B29L 2031/3041 Trim panels
• CPC Class Codes: B60R 13/02 Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners B60R13/01 takes precedence ; padded linings for the vehicle interior B60R21/04; arrangements or adaptations of floor mats or carpets in vehicles B60N3/04; internal lining for trains B61D17/18
• CPC Class Codes: B60R 13/08 Insulating elements, e.g. for sound insulation sound insulating linings for trains B61D17/185; drivers' cabs for load-carrying vehicles insulated against vibrations or noise B62D33/0604; thermal or acoustic insulation of engines F02B77/11; damping of sounds using compensation by electro-acoustic methods G10K11/178

Abstract

A method of forming a panel is disclosed. The method comprises forming a flexible skin; coupling a compressible material to the skin; providing a stitching to the skin and compressible material combination; then positioning the skin and compressible material in a mold; and forming a rigid substrate around the skin and compressible material and a portion of the stitching for providing a first soft region wherein the compressible material is disposed between the skin and the substrate so that a first soft region is defined by the compressible material.

Claims

1. A method of forming a trim panel for a vehicle comprising:

providing a coverstock comprising a skin layer and a compressible layer;

adding a stitching to the coverstock;

positioning the coverstock in a mold;

compressing the compressible material by introducing a molten polymeric material to the mold to form a rigid substrate that is bonded to the coverstock and the stitching; and

removing the panel from the mold so that the compressible material can expand around the stitching.

2. The method of claim 1 wherein the skin layer is formed by vacuum forming and trimming a sheet.

3. The method of claim 2 wherein the skin layer is thermoplastic olefin.

4. The method of claim 1 wherein the compressible layer is coupled to the skin layer.

5. The method of claim 1 wherein the compressible layer comprises a foam material.

6. The method of claim 5 wherein the foam material is a closed cell foam.

7. The method of claim 5 wherein the foam material is bonded to the skin layer.

8. The method of claim 1 wherein the trim panel is a door trim panel.

9. The method of claim 1 further comprising providing a second soft region defined by a portion of the skin layer that is in direct contact with the substrate.

10. The method of claim 1 wherein the step of forming the substrate comprises injection molding a thermoplastic material.

11. The method of claim 1 further comprising the step of forming a recess in the substrate and encapsulating at least one edge of the coverstock within the molten polymeric material that forms a portion of the substrate that defines the recess.

12. The method of claim 1 wherein a portion of the stitching is encapsulated by the molten polymeric material.

13. The method of claim 1 wherein the step of compressing the compressible material results in the compressible layer being in direct contact with the rigid substrate.

14. The method of claim 13 wherein the step of compressing the compressible material results in the skin layer being in direct contact with the compressible material.

15. The method of claim 1 wherein the step of compressing the compressible material results in the skin layer being in direct contact with the compressible material and the rigid substrate.