Method for manufacturing a linear vibration welded carpeted panel

• US 5,705,003 A
• Filed: 05/17/1996
• Issued: 01/06/1998
• Est. Priority Date: 12/21/1992
• Status: Expired due to Fees

• Current Assignee: Visteon Global Technologies Incorporated (Visteon Corporation)
• Original Assignee: Ford Motor Company
• Inventors: Wisniewski, Aaron S., Farrow, Samuel, Debbaudt, Paul E., Walker, Lee Avrial
• Primary Examiner(s): CRISPINO, RICHARD D
• Application Number:
  US08/651,187
• Time in Patent Office: 599 Days
• Field of Search: 156/73.5, 156/75.6, 156/91, 156/308.2, 156/309.6, 156/228
• US Class Current: 156/73.5
• CPC Class Codes: B29C 65/0618 Linear
• CPC Class Codes: B29C 66/1122 Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• CPC Class Codes: B29C 66/4724 said single elements being appliques, e.g. in the form of a text or drawing
• CPC Class Codes: B29C 66/5326 said single elements being substantially flat
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/712 the composition of one of the parts to be joined being different from the composition of the other part
• CPC Class Codes: B29C 66/80 General aspects of machine operations or constructions and parts thereof
• CPC Class Codes: B29C 66/81429 comprising a single tooth
• CPC Class Codes: B29C 66/81433 being toothed, i.e. comprising several teeth or pins comprising a single tooth B29C66/81429, or being patterned
• CPC Class Codes: B29C 66/81461 being multi-lamellar or segmented, i.e. comprising a plurality of strips, plates or stacked elements
• CPC Class Codes: B29K 2023/06 PE, i.e. polyethylene
• CPC Class Codes: B29K 2023/12 PP, i.e. polypropylene
• CPC Class Codes: B29K 2027/06 PVC, i.e. polyvinylchloride
• CPC Class Codes: B29K 2055/02 ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers
• CPC Class Codes: B29L 2031/3005 Body finishings
• CPC Class Codes: B29L 2031/732 Floor coverings piles carpets B29L2031/7652; for vehicles B29L2031/3017
• CPC Class Codes: B32B 2310/028 using vibration, e.g. sonic or ultrasonic
• CPC Class Codes: B32B 37/04 characterised by the partial melting of at least one layer

Abstract

The present invention relates to a method of producing a carpeted vehicle interior panel. A rigid backing having a carpeted surface and a mating surface is molded such that the backing mating surface is 3-dimensional and self-supporting after molding. The backing is overlaid atop the panel with the mating surface juxtaposed a mating surface of the panel. The backing is secured to the panel by linear welding.

Claims

1. A method of producing a carpeted vehicle interior panel comprising the steps of:

providing a rigid backing having a carpeted surface and a mating surface;

molding said backing such that said backing mating surface is three-dimensionally contoured shaped, said backing being self-supporting after molding;

overlaying said backing atop a panel, said backing mating surface juxtaposed a three-dimensionally contoured shaped mating surface of said panel; and

securing said backing to said panel by linear vibration welding, whereby said backing mating surface welds to said panel mating surface to form said carpeted vehicle interior panel.

2. The method of claim 1, further comprising the step of:

rendering said backing mating surface permeable to said welded panel mating surface, said welding causing said panel mating surface to soften and permeate said backing mating surface.

3. The method of claim 2, wherein said rendering step comprises:

securing a permeable layer to said backing, said permeable layer juxtaposed said panel mating surface, said welding causing said panel mating surface to soften and permeate said permeable layer.

4. The method of claim 1, further comprising forming positioning means on said backing mating surface and said panel mating surface, and aligning said backing positioning means with said panel positioning means prior to said welding step.

5. A method of producing a carpeted vehicle interior panel comprising the steps of:

providing a rigid backing having a carpeted surface and a permeable layer;

molding said backing such that said backing is three-dimensionally contoured shaped and self-supporting and forming positioning means in said backing;

overlaying said backing atop a panel, said backing positioning means aligning with positioning means on said panel, said permeable layer juxtaposed a three-dimensionally contoured shaped mating surface of said panel; and

securing said backing to said panel by linear vibration welding, said welding causing said panel mating surface to soften and permeate said permeable layer to form said carpeted vehicle interior panel.