Method for making a supplemental impact restraint door and instrument panel system from single, unitary cover

• US 5,252,164 A
• Filed: 12/21/1992
• Issued: 10/12/1993
• Est. Priority Date: 12/21/1992
• Status: Expired due to Term

• Current Assignee: Collins & Aikman Holdings SA de CV
• Original Assignee: Davidson Textron Inc. (Textron Inc)
• Inventors: Mills, Daniel H.
• Primary Examiner(s): Ball, Michael W.
• Assistant Examiner(s): CRISPINO, RICHARD D
• Application Number:
  US07/993,675
• Time in Patent Office: 295 Days
• Field of Search: 156/196, 156/212, 156/242, 156/245, 156/253, 156/267, 156/285, 156/297, 156/311, 280/728 B, 280/728 R, 280/732
• US Class Current: 156/212
• CPC Class Codes: B29C 2793/00 Shaping techniques involving a cutting or machining operation
• CPC Class Codes: B29C 63/04 by folding, winding, bending or the like
• CPC Class Codes: B29L 2031/3008 Instrument panels
• CPC Class Codes: B60R 21/215 characterised by the covers for the inflatable member B60R21/2176 takes precedence
• CPC Class Codes: Y10T 156/1028 by bending, drawing or stretch forming sheet to assume shape of configured lamina while in contact therewith
• CPC Class Codes: Y10T 156/1057 Subsequent to assembly of laminae
• CPC Class Codes: Y10T 156/108 Flash, trim or excess removal

Abstract

An SIR door and instrument panel are formed by adhering a single, unitary cover material over a preformed door insert member and separate preformed panel insert member. The insert members are sprayed with an adhesive and placed on a support member with the door insert member aligned with and raised above an opening in the panel insert member. The single, unitary cover material is laid over the insert members and vacuum formed thereabout. Thereafter, the cover material is trimmed from the door insert member. The door insert member and cover material are removed from support member. The instrument panel and supplemental impact restraint (SIR) door may thereafter be assembled.

Claims

1. A method for forming a cover material over a preformed door insert and a preformed panel insert of an interior trim product for an automobile, the method including the steps of:

applying an adhesive over the panel insert and the door insert;

placing the panel insert having an opening therein on a support member;

extending a support tower of the support member through the opening;

placing the door insert on the support tower aligned with the opening of the panel insert;

placing a continuous unitary cover material over the panel insert and door insert; and

forming the cover material continuously over and around the door insert and continuously over the panel insert.

2. A method as set forth in claim 1 further including vacuum forming the cover material about the door insert and to the panel insert.

3. A method as set forth in claim 2 further including using plug assists to form the cover material around the door insert.

4. A method as set forth in claim 1 further including spraying the adhesive on the door and panel inserts prior to placing same on the support.

5. A method as set forth in claim 4 further including heating the adhesive on the door and panel inserts and heating the cover material prior to placement on the door and panel inserts.

6. A method as set forth in claim 1 further including trimming the cover material around the door insert and removing same from the support member.