Process for manufacture of decorated panels for vehicle interiors

• US 5,674,445 A
• Filed: 06/07/1995
• Issued: 10/07/1997
• Est. Priority Date: 03/22/1991
• Status: Expired due to Fees

• Current Assignee: Lear Corporation
• Original Assignee: Lear Corporation
• Inventors: Van Ert, Jack
• Primary Examiner(s): DIXON, MERRICK L
• Application Number:
  US08/484,694
• Time in Patent Office: 853 Days
• Field of Search: 156/245, 156/212, 156/228, 156/580, 264/249, 264/243, 264/259, 264/257, 264/163, 425/408, 425/412
• US Class Current: 264/249
• CPC Class Codes: B29C 2063/022 the junction being located in a groove
• CPC Class Codes: B29C 43/18 incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles B29C43/206 takes precedence
• CPC Class Codes: B29C 51/082 by shaping between complementary mould parts
• CPC Class Codes: B29C 51/12 of articles having inserts or reinforcements
• CPC Class Codes: B29C 51/14 using multilayered preforms or sheets
• CPC Class Codes: B29C 51/145 having at least one layer of textile or fibrous material combined with at least one plastics layer
• CPC Class Codes: B29C 51/16 Lining or labelling
• CPC Class Codes: B29L 2009/001 the layers being loose
• CPC Class Codes: B29L 2031/3005 Body finishings
• CPC Class Codes: B29L 2031/3014 Door linings
• CPC Class Codes: B32B 2323/10 Polypropylene
• CPC Class Codes: B32B 2605/003 Interior finishings
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/30 comprising vinyl (co)polymers; comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 3/04 characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
• CPC Class Codes: B44C 5/0453 produced by processes involving moulding
• 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 2013/0281 made of a plurality of visible parts
• CPC Class Codes: B60R 2013/0293 : Connection or positioning of adjacent panels
• 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 156/1031 : with preshaping of lamina
• CPC Class Codes: Y10T 156/108 : Flash, trim or excess removal
• CPC Class Codes: Y10T 428/17 : Three or more coplanar interfitted sections with securing means
• CPC Class Codes: Y10T 428/23929 : Edge feature or configured or discontinuous surface
• CPC Class Codes: Y10T 428/23979 : Particular backing structure or composition
• CPC Class Codes: Y10T 428/24603 : Fiber containing component
• CPC Class Codes: Y10T 428/24612 : Composite web or sheet

Abstract

Decorated panels for automobile interiors, including method, apparatus and a manufacture of a formed decorative panel insert assembly with down turned edge and the decorative panel insert assembly attached to mounting panel stock by embedment of the down turned edge in a groove in the mounting panel stock and pimple protrusions and projecting flange edge coined into the groove sidewall of the mounting panel stock.

Claims

1. A process for making a decorative panel, comprising:

softening a sheet of a mounting panel stock material;

placing the softened sheet onto a first die section of a compression press, so that the sheet overlies a groove in the first die section;

positioning a pre-formed, contoured decorative insert into conforming contact with a second die section of the compression press, the insert having a projecting edge configured to fit into the groove of the first die section; and

pressing the insert and mounting panel into close conforming contact with each other between the first and second die sections so that the projecting edge of the insert extends into said groove under conditions effective to press an underlying portion of the softened sheet into the groove and thereby embed the projecting edge of the insert in the softened sheet, wherein the projecting edge presses the underlying portion of the softened sheet into the groove by itself without the aid of other forming means;

wherein the pressing step further comprises a step of pressing lateral protrusions formed on a rear side, and a flange edge formed on a front side, of the projecting edge of the insert into an outer surface of the heat-softened sheet disposed in the groove, which protrusions and flange edge coin into the sheet material in a manner effective to hinder removal of the embedded insert edge from the sheet.

2. The process of claim 1, wherein the sheet is made of a thermoplastic material, and the softening step further comprises heating the sheet.

3. The process of claim 1, wherein the sheet is made of a thermoplastic material, and the softening step further comprises heating the sheet.

4. The process of claim 3, further comprising forming the sheet material by bonding a decorative thermoplastic overlay having a central opening onto a sheet of thermoplastic material lacking such a central opening, wherein the central opening is covered by the decorative insert after the pressing step.

5. The process of claim 1, further comprising forming the sheet material by bonding a decorative thermoplastic overlay having a central opening onto a sheet of thermoplastic material lacking such a central opening, wherein the central opening is covered by the decorative insert after the pressing step.

6. The process of claim 1, further comprising forming the pre-formed, contoured decorative insert by bonding a thermoplastic backing to a surface material made of a fabric.