Fabrication of multiple color gauge and textured interior auto components

• US 5,773,115 A
• Filed: 10/22/1997
• Issued: 06/30/1998
• Est. Priority Date: 05/01/1996
• Status: Expired due to Fees

• Current Assignee: Collins & Aikman Holdings SA de CV
• Original Assignee: Davidson Textron Inc. (Textron Inc)
• Inventors: Ash, Robert A.
• Primary Examiner(s): THOMAS, ALEXANDER S
• Application Number:
  US08/956,201
• Time in Patent Office: 251 Days
• Field of Search: 428/57, 428/58, 428/61, 428/31
• US Class Current: 428/57
• CPC Class Codes: B29C 2063/022 the junction being located in a groove
• CPC Class Codes: B29C 53/36 Bending and joining, e.g. for making hollow articles B29C53/56 takes precedence
• CPC Class Codes: B29C 63/02 using sheet or web-like material B29C63/26 and B29C63/38 take precedence
• CPC Class Codes: B29C 65/58 Snap connection
• CPC Class Codes: B29C 65/7847 using vacuum to hold at least one of the parts to be joined vacuum work holders in general B25B11/005
• 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 66/1312 Single flange to flange joints, the parts to be joined being rigid the parts to be joined being flexible B29C66/133
• CPC Class Codes: B29C 66/43 Joining a relatively small portion of the surface of said articles B29C66/45 takes precedence
• CPC Class Codes: B29C 66/54 Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
• 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 66/723 being multi-layered B29C66/7292, B29C66/72941 take precedence
• CPC Class Codes: B29C 66/7392 characterised by the material of at least one of the parts being a thermoplastic
• CPC Class Codes: B29C 66/8221 Scissor or lever mechanisms, i.e. involving a pivot point
• CPC Class Codes: B29C 66/83241 cooperating pivoting tools
• CPC Class Codes: B29K 2027/06 PVC, i.e. polyvinylchloride
• CPC Class Codes: B29L 2031/3014 Door linings
• CPC Class Codes: B32B 1/00 Layered products having a non-planar shape
• CPC Class Codes: B32B 2307/402 Coloured
• CPC Class Codes: B32B 2605/00 Vehicles
• 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: B32B 3/06 : for securing layers together; for attaching the product to another member, e.g. to a support , or to another product, e.g. groove/tongue, interlocking
• 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 13/0206 : Arrangements of fasteners and clips specially adapted for attaching inner vehicle liners or mouldings devices for fastening or securing F16B
• CPC Class Codes: B60R 13/0275 : comprising removable or hinged parts for accessing storage compartments B60R7/04; for airbag deployment B60R21/215
• 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 156/1031 : with preshaping of lamina
• CPC Class Codes: Y10T 428/19 : Sheets or webs edge spliced or joined

Abstract

An automotive trim panel is made by using an apparatus and method that bond together two trim coverstock segments having different colors, gauges or textures and two rigid substrate components into a single trim panel with the two coverstock segments meeting along a finished joint line. The method includes joining the coverstock segments together to form a rough seam, supporting the substrate components on two spaced-apart movable mold components with each substrate component having a mating flange that extends into the space between the mold components, applying an adhesive layer to the substrate upper surfaces, heating the joined coverstock segments and vacuum or positive air pressure-forming them across the substrate upper surfaces with the rough seam lying midway between the spaced-apart mold components. Pressure is then applied along the rough seam to infold the coverstock between the mold components while moving the mold components toward a clamped position that sandwiches the infolded coverstock portion between the substrate mating flanges and fastens them together with a pre-mounted fastener. The method forms a finished styling line between the dissimilar coverstock segments and hides the rough seam.

Claims

1. An automotive trim panel assembly comprising:

a first coverstock segment having an outer surface and an inner surface and a mating edge disposed along a portion of a common perimeter of said outer surface and inner surface;

a second coverstock segment having an outer surface and an inner surface and a mating edge disposed along a portion of a common perimeter bounding said outer surface and said inner surface, said second coverstock segment bonded to said first coverstock segment along said respective mating edges forming a rough seam that joins said coverstock segments into a composite coverstock and said outer surfaces into a single composite outer surface;

a first rigid substrate component bonded to said first coverstock inner surface;

a second rigid substrate component bonded to said second coverstock inner surface;

each said substrate component including a perimeter with a mating flange extending inward from along a portion of each said substrate perimeter; and

said composite coverstock including an infold formed along said rough seam and projecting inward and sandwiched between said substrate mating flanges forming a pinched junction at said composite outer surface and concealing said rough seam.

2. A trim panel assembly as defined in claim 1 further including a fastener having a first end connected to one of said substrate mating flanges and a second end connected to the other of said substrate mating flanges, said fastener connecting and holding said substrate mating flanges together in a parallel disposition on either side of said coverstock infold.

3. A trim panel assembly as defined in claim 2 wherein said fastener comprises a spring clip.

4. A trim panel assembly as defined in claim 1 wherein said mating flanges are disposed perpendicular to said composite coverstock outer surface.

5. A trim panel assembly as defined in claim 1 further including an adhesive layer disposed between said composite coverstock and said substrate components.