Vehicle trim panel

• US 5,951,802 A
• Filed: 04/10/1996
• Issued: 09/14/1999
• Est. Priority Date: 04/11/1995
• Status: Expired due to Term

• Current Assignee: Marley Automotive Components Limited
• Original Assignee: Marley Automotive Components Limited
• Inventors: Deeks, Alan Robert
• Primary Examiner(s): CRISPINO, RICHARD D
• Application Number:
  US08/630,576
• Time in Patent Office: 1,252 Days
• Field of Search: 156/214, 156/228, 156/267, 156/245, 156/222, 156/256, 269/39.1
• US Class Current: 156/214
• CPC Class Codes: B29B 11/06 by moulding the material
• CPC Class Codes: B29C 2791/006 Using vacuum
• CPC Class Codes: B29C 2793/0045 Perforating
• CPC Class Codes: B29C 33/12 with incorporated means for positioning inserts, e.g. labels positioning reinforcements B29C70/541
• CPC Class Codes: B29C 44/569 Shaping and joining components with different densities or hardness
• CPC Class Codes: B29C 51/08 Deep drawing or matched-mould forming, i.e. using mechanical means only
• CPC Class Codes: B29C 51/10 Forming by pressure difference, e.g. vacuum
• CPC Class Codes: B29C 65/48 using adhesives , i.e. using supplementary joining material; solvent bonding
• 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 66/727 being porous, e.g. foam
• CPC Class Codes: B29C 70/78 Moulding material on one side only of the preformed part
• CPC Class Codes: B29K 2023/06 PE, i.e. polyethylene
• CPC Class Codes: B29K 2023/10 Polymers of propylene
• CPC Class Codes: B29K 2023/12 PP, i.e. polypropylene
• CPC Class Codes: B29K 2105/04 cellular or porous
• CPC Class Codes: B29L 2031/3005 Body finishings
• CPC Class Codes: Y10T 156/1031 with preshaping of lamina
• CPC Class Codes: Y10T 156/1062 Prior to assembly
• CPC Class Codes: Y10T 156/108 Flash, trim or excess removal

Abstract

A method for making a vehicle trim panel includes bonding an interior lining material to a preformable foam sheet and preforming the bonded lining material and foam sheet to provide a preformed blank, and joining the preformed blank to a second lining material and bonding both the preformed blank and the second lining material to a substrate to make the vehicle trim panel.

Claims

1. A method of making a vehicle trim panel, comprising bonding a first interior lining material to a preformable foam sheet to form a blank, preforming the blank to make a preformed blank having a contoured shape, joining the preformed blank to a second interior lining material at a join, and then bonding both the preformed blank and the second lining material to a substrate.

2. A method as claimed in claim 1, wherein the contoured shape of the preformed blank includes a discontinuity.

3. A method as claimed in claim 2, wherein the discontinuity comprises a stepped portion.

4. A method as claimed in claim 1, comprising trimming the edge of the preformed blank prior to joining it to the second interior lining material.

5. A method as claimed in claim 1, wherein the contoured shape of the preformed blank includes a discontinuity.

6. A method as claimed in claim 5, wherein the discontinuity comprises a stepped portion.

7. A method as claimed in claim 6, wherein the stepped portion is located at or adjacent to the join between the preformed blank and the second interior lining material.

8. A method as claimed in claim 7, comprising trimming the edge of the preformed blank prior to joining it to the second interior lining material.

9. A method as claimed in claim 5, wherein the discontinuity is located at or adjacent to the join between the preformed blank and the second interior lining material.

10. A method as claimed in claim 9, comprising trimming the edge of the preformed blank prior to joining it to the second interior lining material.

11. A method as claimed in claim 1, wherein the bonding of the preformed blank to the substrate takes place between first and second pressing tools.

12. A method as claimed in claim 11, wherein the preformed blank and the substrate are supported between said first and second pressing tools which are brought together in a pressing operation, the substrate being pressed to shape it and the preformed blank being bonded thereto during said pressing operation.

13. A method as claimed in claim 12, wherein the preformed blank is suspended between the first and second pressing tools by means of laterally spaced supports.

14. A method as claimed in claim 1, wherein the foam sheet is perforated whereby the perforations allow the escape of air and thus avoid or minimize the formation of bubbles between the preformed blank and the substrate.

15. A method of making a vehicle trim panel, comprising bonding a first interior lining material to a preformable foam sheet to form a blank, preforming the blank to make a preformed blank having a contoured shape, joining the preformed blank to a second interior lining matertial at a join, suspending the preformed blank and the second lining material from supports to position the preformed blank and second lining material between first and second pressing tools, placing a substrate between the first and second pressing tools, and then bringing together the first and second pressing tools in a pressing operation so as to shape the substrate and to bond both the preformed blank and the second lining material to the substrate during said pressing operation.