HIDDEN LAMP MANUFACTURE PROCESS

• US 20100212819A1
• Filed: 10/12/2009
• Published: 08/26/2010
• Est. Priority Date: 02/22/2009
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Li, Chi, Igoe, Denis Patrick, Gardner, Cornel Lewis, Salter, Stuart C., Singer, Jeffrey
• Granted Patent: US 8,475,017 B2
• Time in Patent Office: Days
• US Class Current: 156/221
• CPC Class Codes: B60Q 3/54 Lighting devices embedded in interior trim, e.g. in roof liners
• CPC Class Codes: B60Q 3/74 for overall compartment lighting; for overall compartment lighting in combination with specific lighting, e.g. room lamps with reading lamps general lighting mounted on specific fittings B60Q3/20; general lighting for mass transit vehicles B60Q3/43
• CPC Class Codes: B60Q 3/82 Switches specially adapted for vehicle interior lighting, e.g. switching by tilting the lens
• 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 13/0212 Roof or head liners movable head-liners B60J7/0007
• CPC Class Codes: B60R 13/0243 Doors
• CPC Class Codes: B60R 2013/0287 integrating other functions or accessories
• CPC Class Codes: Y10T 156/1043 Subsequent to assembly
• CPC Class Codes: Y10T 29/49622 Vehicular structural member making
• CPC Class Codes: Y10T 29/49817 with other than ancillary treating or assembling

Abstract

A method for making a vehicle interior panel including positioning a slipsheet on a film or fabric liner. The liner is placed on a substrate board. The liner and substrate board are formed into an interior panel. A cavity is formed by removing a portion of the substrate board from the interior panel adjacent to the slipsheet position. A lamp is positioned in the cavity.

Claims

1. A method for making a vehicle interior panel comprising:

positioning a slipsheet on a liner;

placing the liner on a substrate board;

forming the liner and substrate board into an interior panel;

forming a cavity by removing a portion of the substrate board from the interior panel adjacent to the slipsheet position; and

positioning a lamp in the cavity.

2. The method of claim 1, further comprising:

adhering the lamp onto the interior panel.

3. The method of claim 1, wherein the step of forming the liner further comprises:

heating the liner and substrate board and molding the substrate board to form the vehicle interior panel.

4. The method of claim 1, wherein the step of positioning a slipsheet further comprises:

positioning a mylar slipsheet on the liner.

5. The method of claim 1, further comprising:

removing excess liner material and substrate material on an outer edge of the interior panel shape.

6. The method of claim 1, wherein the step of forming a lamp aperture further comprises:

using a water jet to cut away substrate material.

7. The method of claim 1, further comprising:

positioning a proximity sensor adjacent to the lamp aperture.

8. A method for making a vehicle interior panel comprising:

forming an interior panel with a liner, a substrate, and a removable slipsheet disposed therebetween;

removing a portion of the substrate board adjacent to the slipsheet to form a cavity;

positioning a lamp in the cavity; and

displaying a visual indicator on an interior side of the interior panel that denotes the position of the lamp behind the liner.

9. The method of claim 8, further comprising:

positioning a proximity sensor adjacent to the lamp aperture.

10. The method of claim 9, further comprising:

installing a light source in the cavity that emits light through the liner.

11. The method of claim 10, wherein the step of positioning a lamp in the cavity further comprises:

installing at least one light emitting diode in the lamp.

12. The method of claim 11, wherein the step of positioning a lamp in the cavity further comprises:

installing a light diffuser between the liner and the lamp.

13. The method of claim 8, further comprising:

operably connecting a lens on the lamp that is visible through the liner.

14. The method of claim 8, further comprising:

printing indicia on the liner below the lamp.

15. A method of positioning a vehicle lamp comprising:

forming an interior panel from a liner and a substrate board;

forming a cavity in the interior panel by removing a portion of the substrate board from the liner;

positioning a lamp in the cavity; and

displaying a visual indicator on an interior side of the interior panel that denotes the position of the lamp behind the liner.

16. The method of claim 15, further comprising:

installing a light source in the cavity that emits light through the liner.

17. The method of claim 15, wherein the step of installing a light source further comprises:

installing a light emitting diode in the cavity that emits light visible on the interior side of the interior panel.

18. The method of claim 15, further comprising:

operably connecting a lens on the lamp that is visible through the liner.

19. The method of claim 15, further comprising:

printing indicia on the liner below the lamp.

20. The method of claim 15, wherein the step of forming an interior panel from a liner and a substrate board further comprises:

using a liner that includes a first textured material adjacent to the substrate board and a second textured material adjacent to the cavity.