DECORATIVE RESILIENT LAMINAR PANEL

• US 3,867,240 A
• Filed: 03/26/1973
• Issued: 02/18/1975
• Est. Priority Date: 05/22/1972
• Status: Expired due to Term

• Current Assignee: Indian Head Industries Inc.
• Original Assignee: Ralph G. Doerfling
• Inventors: Doerfling, Ralph G.
• Primary Examiner(s): Ansher, Harold
• Application Number:
  US05/344,629
• Time in Patent Office: 694 Days
• Field of Search: 161/112,113,161,109,404,39-45 181/33G,33GA,33GC,33GB,DIG.1 296/137R,137A
• US Class Current: 428/71
• CPC Class Codes: B29C 44/56 After-treatment of articles, e.g. for altering the shape
• CPC Class Codes: B29L 2031/3011 Roof linings
• CPC Class Codes: B32B 2325/00 Polymers of vinyl-aromatic compounds, e.g. polystyrene
• CPC Class Codes: B32B 2327/06 PVC, i.e. polyvinylchloride
• CPC Class Codes: B32B 2375/00 Polyureas; Polyurethanes
• CPC Class Codes: B32B 2398/20 Thermoplastics
• CPC Class Codes: B32B 27/10 of paper or cardboard
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B60R 13/0225 self supporting head liners
• CPC Class Codes: B60R 13/0815 Acoustic or thermal insulation of passenger compartments wall or roof liners integrating the insulating function B60R13/02; insulating floor mats or carpets B60N3/04
• CPC Class Codes: B60R 13/0892 for humidity insulation sealing strips B60R13/06
• CPC Class Codes: Y10T 428/233 Foamed or expanded material encased
• CPC Class Codes: Y10T 428/24331 including nonapertured component
• CPC Class Codes: Y10T 428/24504 Component comprises a polymer [e.g., rubber, etc.]
• CPC Class Codes: Y10T 428/24595 and varying density
• CPC Class Codes: Y10T 428/24612 Composite web or sheet
• CPC Class Codes: Y10T 428/249961 With gradual property change within a component
• CPC Class Codes: Y10T 428/249981 Plural void-containing components

Abstract

An improved decorative resilient laminar panel and the method of fabricating said panel which is characterized by its shaperetaining compound contour and selected embossments over predetermined areas thereof and which comprises a perforated thermoplastic resin foam disposed between a pair of perforated cover sheets which are coated with a moisture-resistant sealing material. The resilient laminar panel is particularly applicable for use as automobile interior trim panels in which the exposed face surfaces thereof are provided with decorative coatings or decorative plies to enhance the aesthetic and functional characteristics thereof.

Claims

1. A TRIM COMPRISING A RESILIENT LAMINAR PANEL OF A PRESELECTED SHAPE-RETAINING CONTOUR INCLUDING A THERMOPLASTIC RESIN FOAM CORE, A COVER SHEET OVERLYING EACH FACE SURFACE OF SAID FOAM CORE AND BONDED THERETO OVER SUBSTANTIALLY THE ENTIRE SURFACE THEREOF, EACH SAID COVER SHEET AND SAID FOAM CORE FORMED WITH A PLURALITY OF PERFORATION EXTENDING THERETHROUGH FROM ONE FACE TO THE OPPOSITE FACE OF SAID PANEL AND DISTRIBUTED AT SPACED INTERVALS OVER SUBSTANTIALLY THE ENTIRE AREA OF SAID PANEL, SAID FOAM CORE BEING OF A GREATER DENSITY IN THE REGION ADJACENT TO SAID PERFORATION THERETHROUGH THAN IN THE REGION SPACED TO SAID PERFORATIONS, A SEALER COATING OVERLYING SUBSTANTIALLY THE ENTIRE EXTERIOR SURFACES OF THE COVER SHEETS AND INNER SURFACES OF SAID PERFORATIONS, AND A PERVIOUS DECORATIVE COATING EXTENDING OVER SUBSTANTIALLY THE ENTIRE FACE SURFACE OF ONE OF SAID COVER SHEETS AND SECURED THERETO.

2. The trim panel as defined in claim 1, wherein said foam core comprises polystyrene foam.

3. The trim panel as defined in claim 1, wherein said cover sheet comprises kraft paper.

4. The trim panel as defined in claim 1, wherein said sealer coating comprises a moisture-impervious lacquer coating.

5. The trim panel as defined in claim 1, wherein one of said cover sheets extends inwardly for at least a portion of the length of said perforation in the form of an annular lining over the internal surfaces thereof.

6. The trim panel as defined in claim 1, formed with embossments over a preselected areas thereof.

7. The trim panel as defined in claim 1, formed with a compound curvature and suitable for use as an automobile headliner.

8. The trim panel as defined in claim 1, wherein said decorative coating comprises a pervious decorative ply adhesively bonded to the face surface of one said cover sheet.

9. The trim panel as defined in claim 8, wherein said decorative ply comprises a perforated vinyl film.

10. The trim panel as defined in claim 8, wherein said decorative ply comprises a pervious paper sheet.