Method for producing a covering element made of breakable material

• US 6,547,910 B1
• Filed: 02/22/2001
• Issued: 04/15/2003
• Est. Priority Date: 03/08/1999
• Status: Expired due to Fees

• Current Assignee: Daimler Chrysler Company LLC (Stellantis NV)
• Original Assignee: Daimler Chrysler Company LLC (Stellantis NV)
• Inventors: Skrzypek, Uwe, Benzing, Thomas, Jambor, Arno
• Primary Examiner(s): YAO, SAMCHUAN CUA
• Application Number:
  US09/700,047
• Time in Patent Office: 782 Days
• Field of Search: 156/196, 156/212, 156/230, 156/241, 156/245, 156/247, 156/267, 156/285, 156/236
• US Class Current: 156/212
• CPC Class Codes: B29C 2791/006 Using vacuum
• CPC Class Codes: B29C 2791/007 Using fluid under pressure
• CPC Class Codes: B29C 43/184 shaped by the compression of the material during moulding
• CPC Class Codes: B29C 63/04 by folding, winding, bending or the like
• CPC Class Codes: B29C 63/16 applied by "rubber" bag or diaphragm
• CPC Class Codes: B29L 2031/3014 Door linings
• CPC Class Codes: B32B 2318/04 Stone
• CPC Class Codes: B32B 33/00 Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
• CPC Class Codes: B32B 37/10 characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
• 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: Y10T 156/1028 by bending, drawing or stretch forming sheet to assume shape of configured lamina while in contact therewith
• CPC Class Codes: Y10T 156/108 Flash, trim or excess removal

Abstract

A method for producing a trim panel with a thin decorative layer on a supporting element. The thin decorative layer is composed of an organic and/or crystalline material which is frangible in a thin layer, in particular natural stone. The method including the steps of: An adhesive and a nonwoven fabric or a film are applied as a plastic fixing film to a surface of the thin decorative layer. A surface of the supporting element later facing the decorative layer is coated with an adhesive. The supporting element is placed with the side not coated with the adhesive into a lower mold. The decorative layer with the plastic fixing film is roughly cut to size and placed with its uncoated surface onto the surface of the supporting element coated with the adhesive and positioned. An elastic element is positioned on the decorative layer with the plastic fixing film. Pressure is applied to the side of the elastic element facing away from the decorative layer, the decorative layer adapting itself to the form of the surface of the supporting element and adhesively bonding to the supporting element. The composite structure composed of the supporting element and the decorative layer is removed from the lower mold and an outer contour of the composite structure composed of the supporting element and the decorative layer is machined to the final dimensions. The plastic fixing film is removed from the decorative layer by the action of heat and/or solvent.

Claims

1. A method for producing a trim panel with a thin decorative layer on a supporting element, the thin decorative layer being composed of at least one of an organic and a crystalline material which is frangible in a thin layer, the method comprising:

applying a plastic fixing film to a first surface of the thin decorative layer;

applying an adhesive to a first surface of a supporting element;

placing a second surface of the supporting element into a lower mold;

sizing the decorative layer and plastic fixing film;

disposing a second surface of the decorative layer adjacent the first surface of the supporting element;

disposing an elastic element on the decorative layer having the plastic fixing film;

applying pressure to a side of the elastic element facing away from the decorative layer so as to adapt the decorative layer to the first surface of the supporting element and so as to adhesively bond the decorative layer to the supporting element as a composite structure;

removing the composite structure from the lower mold;

machining an outer contour of the composite structure to predetermined dimensions; and

removing the plastic fixing film from the decorative layer using at least one of heat and a solvent.

2. The method as recited in claim 1 wherein the decorative layer includes natural stone.

3. The method as recited in claim 1 wherein the plastic fixing film includes a second adhesive and at least one of a nonwoven fabric and a film.

4. The method as recited in claim 1 further comprising segmenting the decorative layer after the applying of the plastic fixing film.

5. The method as recited in claim 1 further comprising supplying thermal energy at a same time as the applying of the pressure so as to heat at least the plastic fixing film.

6. The method as recited in claim 1 wherein the pressure is applied using an upper mold.

7. The method as recited in claim 6 wherein the elastic element is bonded to the upper mold at an area of a negative contour defined by the upper mold.

8. The method as recited in claim 1 wherein the elastic element includes a gas-tight elastic skin connected in a gas-tight manner to the lower mold so as to generate a negative pressure between the lower mold and the elastic skin.

9. The method as recited in claim 1 wherein a fluid press is used in applying the pressure and wherein the elastic element includes an elastic underside of the fluid press.

10. The method as recited in claim 1 further comprising providing the decorative layer with a transparent protective layer.

11. The method as recited in claim 1 wherein the machining of the outer contour includes milling.