Method of producing a vehicle interior lining and vehicle interior lining

• US 20040076814A1
• Filed: 08/19/2003
• Published: 04/22/2004
• Est. Priority Date: 08/19/2002
• Status: Active Grant

• Current Assignee: Arvinmeritor Light Vehicle Systems FRA (Meritor, Inc. (Nevada))
• Original Assignee: Arvinmeritor Light Vehicle Systems FRA (Meritor, Inc. (Nevada))
• Inventors: Schonebeck, Horst
• Granted Patent: US 6,977,019 B2
• Time in Patent Office: Days
• US Class Current: 428/316.6
• CPC Class Codes: B29C 44/145 the lining being a laminate
• CPC Class Codes: B32B 2375/00 Polyureas; Polyurethanes
• CPC Class Codes: B32B 2605/00 Vehicles
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/245 another layer next to it being a foam layer
• CPC Class Codes: B32B 5/32 at least two layers being foamed and next to each other
• CPC Class Codes: Y10T 428/249981 Plural void-containing components

Abstract

A vehicle interior lining having good sound absorbing properties and that is permeable to air is formed from an intermediate product comprising an inside decorative layer and a barrier layer made of open-cell foam. The barrier layer adjoins the rear side of the decorative layer. A foam backing is disposed on the rear side of the intermediate product is provided with a foam backing. The barrier layer prevents the foam backing material from penetrating through toward the decorative layer, eliminating the need for a barrier film and improving sound absorption. The interior lining can be used as a roof lining.

Claims

1. A method of producing a vehicle interior lining comprising:

forming an intermediate product having a decorative layer and an open-cell foam barrier layer, the barrier layer adjoining the rear side of the decorative layer; and

providing a foam backing to the rear side of the intermediate product by a back foaming process that includes applying a liquid plastic to the barrier layer, wherein the barrier layer blocks the liquid plastic to prevent the liquid plastic from penetrating the barrier layer toward the decorative layer.

2. The method according to claim 1, wherein the forming step comprises gluing the barrier and decorative layers to each other.

3. The method according to claim 1, wherein the forming step comprises laminating the barrier and decorative layers together.

4. The method according to claim 1, wherein a fiber mat is applied to the rear side of the layer produced by back foaming during the back foaming process.

5. The method according to claim 1, wherein a fiber mat is embedded in the liquid plastic during the back foaming process.

6. The method according to claim 1, wherein the liquid plastic is directly applied to the barrier layer and comes into contact with the barrier layer during the back foaming process.

7. The method according to claim 1, further comprising introducing fibers into the liquid plastic during the back foaming process, wherein the fibers are distributed in the resulting layer formed by the back foaming process.

8. The method according to claim 7, wherein the fibers are glass fibers introduced into the liquid plastic via a Long Fiber Injection process.

9. The method according to claim 1, further comprising embedding at least one of a fastener and a spacer in the liquid plastic during the back foaming process.

10. A vehicle interior lining, comprising:

a decorative layer;

an open-cell foam barrier layer joined to a rear side of the decorative layer to form an intermediate product; and

a layer at the rear side of the intermediate product and formed via a back foaming process that includes applying liquid plastic to the intermediate product, wherein the barrier layer prevents the liquid plastic from penetrating the barrier layer toward the decorative layer.

11. The vehicle interior lining according to claim 10, wherein the liquid plastic is polyurethane.

12. The vehicle interior lining according to claim 10, wherein the decorative layer is one selected from the group consisting of a textile material, a leather material, and an imitation leather material.

13. The vehicle interior lining according to claim 10, further comprising a fiber mat coupled to the rear side of the layer formed by the back foaming process.

14. The vehicle interior lining according to claim 13, wherein the fiber mat is embedded in the layer formed by the back foaming process.

15. The vehicle interior lining according to claim 10, further comprising a plurality of fibers in the layer formed by the back foaming process.

16. The vehicle interior lining according to claim 15, wherein the plurality of fibers are glass fibers.

17. The vehicle interior lining according to claim 10, further comprising at least one of a fastener and a spacer embedded in the layer formed by the back foaming process.

18. The vehicle interior lining according to claim 10, wherein the barrier layer is permeable to air.

19. The vehicle interior lining according to claim 10, wherein the vehicle interior lining is permeable to air.