Apparatus for producing interior trim component for a motor vehicle

• US 4,802,948 A
• Filed: 12/05/1986
• Issued: 02/07/1989
• Est. Priority Date: 01/17/1985
• Status: Expired due to Fees

• Current Assignee: Ford Motor Company
• Original Assignee: Ford Motor Company
• Inventors: Hartmann, Klaus, Wessel, Heinz, Zimmermann, Willibald
• Primary Examiner(s): Weston, Caleb
• Application Number:
  US06/938,184
• Time in Patent Office: 795 Days
• Field of Search: 156/245, 156/500, 156/569, 156/570, 156/566, 156/580, 156/581, 156/583.91, 156/556, 156/558, 425/412, 425/419, 425/344, 425/346, 425/347, 425/404, 425/412, 425/413, 425/436 R, 425/519, 414/222, 414/225, 414/751, 271/18, 271/18.3, 271/117, 271/226, 264/113, 264/119, 264/120, 264/250, 264/257, 264/293
• US Class Current: 156/500
• CPC Class Codes: B27N 3/22 Charging or discharging
• CPC Class Codes: B27N 5/00 Manufacture of non-flat articles
• CPC Class Codes: B29C 2043/188 thermosetting adhesives, e.g. polyurethane adhesives
• CPC Class Codes: B29C 2043/3613 applying pressure locally
• CPC Class Codes: B29C 31/00 Handling, e.g. feeding of the material to be shaped , storage of plastics material before moulding; Automation, i.e. automated handling lines in plastics processing plants, e.g. using manipulators or robots discharging moulded articles from the mould B29C37/0003; storage of prepregs or SMC after impregnation or during ageing B29C70/54; baling of rubber B29B15/02
• CPC Class Codes: B29C 51/082 by shaping between complementary mould parts
• CPC Class Codes: B29C 51/261 Handling means, e.g. transfer means, feeding means B29C51/44 takes precedence
• CPC Class Codes: B29C 51/44 Removing or ejecting moulded articles
• CPC Class Codes: B29C 70/46 using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
• CPC Class Codes: B29C 70/461 Rigid movable compressing mould parts acting independently from opening or closing action of the main mould
• CPC Class Codes: B29L 2031/3014 Door linings
• 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: Y10T 156/1768 Means simultaneously conveying plural articles from a single source and serially presenting them to an assembly station
• CPC Class Codes: Y10T 156/1776 Means separating articles from bulk source
• CPC Class Codes: Y10T 156/1778 Stacked sheet source
• CPC Class Codes: Y10T 428/15 Sheet, web, or layer weakened to permit separation through thickness
• CPC Class Codes: Y10T 428/24554 including cellulosic or natural rubber component
• CPC Class Codes: Y10T 428/24612 Composite web or sheet
• CPC Class Codes: Y10T 428/24628 Nonplanar uniform thickness material
• CPC Class Codes: Y10T 428/253 Cellulosic [e.g., wood, paper, cork, rayon, etc.]

Abstract

An interior trim component 1 for a motor vehicle comprises a base 2 of a fibrous base material of approximately 80% wood fibers and approximately 20% synthetic resin fibers, which is compressed and consolidated by the action of pressure and heat into the desired shape. Padding and/or a fabric insert 5 may be placed over selected areas of the surface of the base 2 and a sheet 7 of plastic material is bonded over the whole of the visible side of the base 2, the parts of the plastic sheet 7 overlying the insert 5 having a continuous impressed separation so that they may be removed. The fibrous base material which is in the form of fibrous fleece mats of approximately 20 to 30 mm thickness is consolidatd in a hot-pressing shaping tool at 4000 N/M² and approximately 200° C. to a final thickness approximately one tenth the initial thickness, but is consolidated to a lesser extend in selected surface areas 4 to produce a greater final thickness between one fifth and two fifths the initial thickness, so as to provide a cushioning effect.

Claims

1. An apparatus for producing an interior trim component for a motor vehicle, said component comprising a compressed fiber base and a plastic sheet adhered to at least selected areas of a surface thereof, wherein selected portions of said base are less compressed and thicker than remaining portions of said base, said apparatus comprising a loading station followed by an alignment station followed by a shaping station followed by a sealing station, said shaping station comprising a male mold member and an opposed female mold member, said mold members being moveable relative one another into a closed position defining a gap between them of uneven thickness, whereby in said closed position said mold members are adapted to subject selected areas of a fibrous mat of substantially uniform thickness to different degrees of compression than remaining areas of said mat, and wherein said loading station comprises a first loading frame, a second loading frame and a support surface adapted to support a stack of fibrous mats, each of said loading frames comprising means for releasably gripping a fibrous mat to transport same and being vertically moveable independently of the other, said first loading frame being reciprocally moveably horizontally from a first position over said support surface to a second position over said alignment station, said second loading frame being reciprocally moveable horizontally from a first position over said alignment station to a second position over said shaping station.

2. The apparatus of claim 1, wherein said gripping means comprises a plurality of sets of oppositely disposed, reciprocally moveable pins.

3. The apparatus of claim 1, wherein said alignment station comprises a plurality of moveable rails adapted to contact edges of said fibrous mat.

4. An apparatus for producing an interior trim component for a motor vehicle, said component comprising a compressed fiber base and a plastic sheet adhered to at least selected areas of a surface thereof, wherein selected portions of said base are less compressed and thicker than remaining portions of said base, said apparatus comprising a loading station followed by an alignment station followed by a shaping station followed by a sealing station, said shaping station comprising a male mold member and an opposed female mold member, said mold members being moveable relative one another into a closed position defining a gap between them of uneven thickness, whereby in said closed position said mold members are adapted to subject selected areas of a fibrous mat of substantially uniform thickness to different degrees of compression than remaining areas of said mat, and wherein said male mold member comprises a moveable advancing member adapted to contact and displace a region of said fibrous mat prior to compression molding thereof and to provide a portion of the surface of said male mold during such compression molding.

5. The apparatus of claim 4, wherein said male mold member further comprises a moveable ejector adapted to facilitate removal of said fibrous mat from said shaping station.

6. An apparatus for producing an interior trim component for a motor vehicle, said component comprising a compressed fiber base and a plastic sheet adhered to at least selected areas of a surface thereof, wherein selected portions of said base are less compressed and thicker than remaining portions of said base, said apparatus comprising a loading station followed by an alignment station followed by a shaping station followed by a sealing station, said shaping station comprising a male mold member and an opposed female mold member, said mold members being moveable relative one another into a closed position defining a gap between them of uneven thickness, whereby in said closed position said mold members are adapted to subject selected areas of a fibrous mat of substantially uniform thickness to different degrees of compression than remaining areas of said mat, and wherein said sealing station comprises (a) a receiving member adapted to register with a fibrous mat shaped by said shaping station, and (b) a sealing punch reciprocally moveable relative said receiving member and having a sealing electrode adapted to contact said shaped fibrous mat on said receiving member in a preselected pattern.